Electrochemical activation of water

ABSTRACT

A sprayer apparatus includes a spray nozzle in fluid communication with a reservoir for an aqueous salt solution; at least two electrodes spaced apart from each other integrated into the reservoir; a controller structured to apply electricity to the at least two electrodes, wherein the controller controls an application of electricity to cause a first one of the at least two electrodes to be positively charged and a second one of the at least two electrodes to be negatively charged; and wherein the sprayer apparatus is configured to produce air bubbles during application of electricity, wherein the air bubbles cause agitation and mixing of the aqueous salt solution.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/112,212 (GENE-0001-U01-C01-C01-C01-C01-C01), filed Aug. 24, 2018.

U.S. patent application Ser. No. 16/112,212 is a continuation of U.S.patent application Ser. No. 15/646,686 (GENE-0001-U01-C01-C01-C01-C01),filed Jul. 11, 2017, now U.S. Pat. No. 10,086,412.

U.S. patent application Ser. No. 15/646,686 is a continuation of U.S.patent application Ser. No. 15/404,042 (GENE-0001-U01-C01-C01-C01),filed Jan. 11, 2017, now U.S. Pat. No. 10,016,791. U.S. patentapplication Ser. No. 15/404,042 is a continuation of U.S. patentapplication Ser. No. 15/192,472, filed Jun. 24, 2016(GENE-0001-U01-C01-C01), now U.S. Pat. No. 9,573,171. Application Ser.No. 15/192,472 is a continuation of U.S. patent application Ser. No.14/976,324, filed Dec. 21, 2015 (GENE-0001-U01-C01), now U.S. Pat. No.9,399,823. Application Ser. No. 14/976,324 is a continuation of U.S.patent application Ser. No. 14/055,630, filed Oct. 16, 2013(GENE-0001-U01), now U.S. Pat. No. 9,309,601. Application Ser. No.14/055,630 claims the benefit of U.S. Provisional Application No.61/714,601, filed Oct. 16, 2012 (GENE-0001-P01). Each of the aboveapplications are incorporated by reference in their entirety.

BACKGROUND Field

The inventive methods and systems described herein generally relate toelectrochemical treatment of water to produce cleaning, sanitizing, andantimicrobial solutions.

Description of the Related Art

Many cleaners, sanitizers, disinfectants and antimicrobial productsemploy harsh chemicals, many of which are toxic. These cause problemswhen disposed and make their way into the natural water system.Therefore, there have been a number of attempts to make safe andeffective cleaners, sanitizers, disinfectants and antimicrobials.

There have been various prior art publications describingelectrochemical activation of salt-containing water. It is possible touse these systems for creating solutions useful for cleaning andsanitizing, however, they typically require bulky apparatus andcomplicated means for separating anolytes and catholytes. There remainsa need for cleaning, sanitizing and antimicrobial solutions that arecreated using harmless compounds in a compact apparatus.

SUMMARY

The present disclosure provides natural, common salts, electrochemicallyactivated in an aqueous solution to result in an ECA product which issafe and non-toxic, with properties of a cleaner, sanitizer,disinfectant, degreaser, antimicrobial and the like. The materials usedallow inexpensive production of large amounts of the ECA product at asite where it is being used. This reduces the expenses of purchasing,storing and shipping large amounts of cleaners, sanitizers, degreasers,disinfectants, antimicrobials and the like, especially for largeindustrial uses.

The systems and methods disclosed herein may include a system,comprising at least two electrodes adapted to be immersed in an aqueoussalt solution each disposed at a distance from one another, wherein uponthe application of electricity a first electrode is adapted to bepositively charged and a second electrode is adapted to be negativelycharged and a control module electrically coupled to the electrodes,wherein the control module controls operation of the at least twoelectrodes and wherein the electrodes are coated with iridium whereinthe control module may control the provision of electricity to theelectrodes in a manner to perform ECA of the aqueous salt solution tocreate an ECA product solution. In embodiments, the system mayadditionally include an ECA product solution selected from a groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution.Additionally, the systems and methods disclosed herein may include asalt that is at least one of sodium chloride or a mixture of sodiumchloride and citric acid. The system may include an ECA product solutioncontaining at least HOCl. The system may include a salt which ispotassium carbonate. The system may include an ECA product solutioncontaining at least KOH. The system may include a salt which is presentin a trace amount. In embodiments, the system may include an ECA productsolution containing at least ionized water. The system may include aspray nozzle to distribute the ECA product solution from the system. Thesystem may include a reservoir to collect the ECA product solution. Thesystem may be adapted to provide ECA product solution in a hydraulicfracking application. In embodiments, the system may be adapted toprovide ECA product solution in at least one of an airplane, a vehicle,a cruise ship, a humidifier, a vaporizer, a furnace, a floor scrubber, awarewashing facility, a laundry facility, a shower head, a faucet, afood sprayer, or a custodial sprayer. In embodiments, the system mayinclude a control module programmed to reverse the polarity of theelectrodes after a pre-determined period of time. Additionally thesystem may include an impeller for mixing the solution. The system maybe powered by at least one of line power, a battery, solar energy andkinetic energy. The system may be deployed such that the distancebetween the at least two electrodes is adjustable by at least one of amanual mechanism and an automatic mechanism. In embodiments, the systemmay be deployed such that the distance between the at least twoelectrodes is adjustable in response to a measurement by a sensor.Additionally, the system may be deployed such the distance between theat least two electrodes is controlled by the control module. The systemmay include an ECA product solution generated by the operation of thesystem, wherein the active species is at least one of OH⁻ and Cl⁻.

The systems and methods disclosed herein may include a device,comprising a portable receptacle adapted to contain an aqueous solutionof a carbonate salt, at least two electrodes spaced apart from eachother within the portable receptacle, at least two receptacle contactsbeing electrical contacts disposed on the container, electricallyconnected to the electrodes and a base adapted to receive the receptacleand provide electricity to the receptacle contacts, wherein upon theprovision of electricity to the receptacle contacts, an electrochemicalactivation (ECA) of the aqueous solution is caused in the portablereceptacle to convert the aqueous solution into an ECA product solution.In embodiments, the device may include a carbonate salt, which may bepotassium carbonate (K₂CO₃). The device may include a base with acontrol module that determines the magnitude, timing and polarity of theelectricity provided to the electrodes. In embodiments, the electrodesmay be made of a highly conductive, non- corrosive metal or made oftitanium and have a platinum coating or made of titanium and have aniridium coating. The base and receptacle may include alignment featuresthat cause the receptacle to properly be received by the base. Inembodiments, the device may include a receptacle with a magnet and thebase includes a sensor for detecting when the magnet is in its vicinityindicating that the receptacle has been received by the base. The devicemay include a user interface coupled to the control module forindicating at least one of when ECA is progressing and has beencompleted. In embodiments, the ECA product solution may be selected fromthe group comprising a sanitizing solution, a disinfecting solution, acleaning solution, a degreasing solution, and an antimicrobial solution.In embodiments, the ECA product solution may be generated by operationof such a device. Additionally, the active species of the ECA productsolution generated may be OH⁻. In embodiments, the salt present with thedevice may be in a trace amount.

In embodiments, the systems and methods disclosed herein may include adevice, comprising a portable receptacle adapted to contain an aqueoussolution of a halide salt, at least two electrodes spaced apart fromeach other within the portable receptacle, at least two receptaclecontacts being electrical contacts disposed on the container,electrically connected to the electrodes, and a base adapted to receivethe receptacle and provide electricity to the receptacle contacts,wherein upon provision of electricity, an electrochemical activation(ECA) of the aqueous solution in the portable receptacle is caused toconvert the aqueous solution into an ECA product solution. Inembodiments, the halide salt may be sodium chloride (NaCl) or mixed withcitric acid. The base may include a processor that determines themagnitude, timing and polarity of the electricity provided to theelectrodes. In embodiments, the ECA product solution may be selectedfrom the group comprising a sanitizing solution, a disinfectingsolution, a cleaning solution, a degreasing solution, and anantimicrobial solution. The ECA product solution may be generated by theoperation of the device and in certain embodiments, the active speciesmay be Cl⁻. Additionally, the salt present in the device may be presentin a trace amount.

The systems and methods disclosed herein may include a device forcreating a cleaning solution comprising a portable receptacle adapted tocontain water, at least two electrodes spaced apart from each otherwithin the portable receptacle, at least two receptacle contacts beingelectrical contacts disposed on the container, electrically connected tothe electrodes, a base adapted to receive the receptacle and provideelectricity to the receptacle contacts, wherein upon provision ofelectricity, ionization of the water in the portable receptacle iscaused to convert the water into a cleaning solution. In embodiments,the systems and methods disclosed herein may include the cleaningsolution generated by operation of the device. Additionally, the saltpresent in the device may be present in a trace amount.

The systems and methods disclosed herein may include an immersion wanddevice for immersion into a receptacle containing an aqueous carbonatesalt solution, comprising, an elongated housing having a handle at afirst end and an immersion head at a second end, at least two electrodesspaced apart from each other within the immersion head, a base unitelectrically coupled to the electrodes to provide electricity to theelectrodes, wherein upon provision of electricity, ECA of the aqueouscarbonate salt solution in the receptacle is caused to convert thesolution in-situ into an ECA product solution. The elongated housing maybe extendable to allow the immersion head to extend to the bottom ofvarious sized receptacles. Additionally, the ECA product solution may beselected from the group comprising a sanitizing solution, a disinfectingsolution, a cleaning solution, a degreasing solution, and anantimicrobial solution. ECA product solution may be generated by theoperation of the device. Additionally, the active species of the ECAproduct solution generated by operation of the device may be OH⁻.Furthermore, the salt present in the device may be present in a traceamount.

The systems and methods disclosed herein may include an immersion wanddevice for immersion into a receptacle containing an aqueous metalhalide salt solution, comprising an elongated housing having a handle ata first end and an immersion head at a second end, at least twoelectrodes spaced apart from each other within the immersion head, abase unit electrically coupled to the electrodes to provide electricityto the electrodes, wherein upon provision of electricity, ECA of theaqueous metal halide salt solution in the receptacle is caused toconvert the solution in-situ into an ECA product solution. The elongatedhousing may extendable to allow the immersion head to extend to thebottom of various sized receptacles. The ECA product solution may beselected from the group comprising a sanitizing solution, a disinfectingsolution, a cleaning solution, a degreasing solution, and anantimicrobial solution. An ECA product solution may be generated by theoperation of the system or device and/or the disclosed methods.Additionally, the active species of the ECA product solution generatedmay be Cl⁻. Furthermore, the salt present in the device may be presentin a trace amount.

The systems and methods disclosed herein may include a system forcreating an ECA product solution from an aqueous metal halide saltsolution comprising at least two electrodes adapted to be immersed inthe aqueous metal halide salt solution each disposed at a distance fromone another, wherein upon application of electricity, a first electrodeis adapted to be positively charged and a second electrode is adapted tobe negatively charged, and a control module electrically coupled to theelectrodes, wherein the control module controls operation of the atleast two electrodes. The control module may control the provision ofelectricity to the electrodes in a manner to perform ECA of the aqueousmetal halide salt solution to create an ECA product solution. The systemmay also include a pump that directs at least one of air, water, or themetal halide salt-containing solution to the at least two electrodes. Inembodiments, the metal halide salt may be a metal chloride salt orsodium chloride. The system may operate at variable amperage. Inembodiments, the control module causes the system to operate for aspecific amount of time to deliver a specific amount of electricalenergy. In embodiments, the system may be operated continuously. Thesalt may be a mixture of sodium chloride and citric acid. The salt maybe present in a trace amount. The system may include a control modulewhich causes the system to operate for a specific amount of time todeliver a specific amount of electrical energy to achieve a specificlevel of Free Available Chlorine. The system may include varying theoperation time of the system varies one or more of the products and theconcentration of the products of the ECA.

An included pump may be an air pump that pushes air through the solutionor a water pump that directs the solution to the at least twoelectrodes. The pump may be controlled to vary a speed of flow of thesolution. In embodiments, the ECA product solution may include at leasthypochlorous acid. The system may include electrodes which areiridium-coated. The electrodes may also be disposed at a predeterminedspacing for use in ECA. The system may include a sensor that measures atleast one of FAC and pH. In embodiments, the control module may beprogrammed to reverse the polarity of the electrodes after apre-determined period of time. The system may further include animpeller for mixing the solution. The system may be powered by at leastone of line power, a battery, solar energy and kinetic energy. Inembodiments, the system may operate at less than or equal to 120 Voltsor 240 Volts. The system may operate at 4 Amps, 8 Amps, or at least 10Amps. In embodiments, the time may be at least one minute, five minutes,or ten minutes. In embodiments, the ECA product solution may be selectedfrom the group comprising a sanitizing solution, a disinfectingsolution, a cleaning solution, a degreasing solution, and anantimicrobial solution. The sensor may provide feedback to the controlmodule, wherein the control module modifies operation of the systembased on the sensor feedback. The system may further include a userinterface in communication with the control module, wherein the userinterface is adapted to provide information about the status of at leastone of the operation of the system and a condition of the solutions. AnECA product solution may be generated by the operation of the systemand/or the disclosed methods, and the active species may be Cl⁻.

The systems and methods disclosed herein may include a system forcreating an ECA product solution from an aqueous carbonate saltsolution, comprising at least two electrodes adapted to be immersed inthe aqueous carbonate solution each disposed at a distance from oneanother, wherein upon application of electricity, a first electrode isadapted to be positively charged and a second electrode is adapted to benegatively charged and a control module electrically coupled to the atleast two electrodes, wherein the control module controls operation ofthe at least two electrodes wherein the control module controls theprovision of electricity to the electrodes in a manner to perform ECA ofthe aqueous carbonate solution to create an ECA product solution. Thesystem may also include at a pump that directs at least one of air,water, or the carbonate-containing solution to the at least twoelectrodes. Additionally, the system may further include an aqueouscarbonate salt which is a metal carbonate salt solution of potassiumcarbonate. In embodiments, the system may operate at variable amperage.The system may include a control module causes the system to operate fora specific amount of time to deliver a specific amount of electricalenergy. The system may be operated continuously. The system may includea control module which causes the system to operate for a specificamount of time to deliver a specific amount of electrical energy toachieve a specific level of potassium hydroxide. The system may includevarying the operation time of the system varies one or more of theproducts and the concentration of the products of the ECA. Inembodiments, the system may include a pump which is an air pump thatpushes air through the solution. The pump may be controlled to vary aspeed of flow of the solution. In embodiments, the system may includeelectrodes that are iridium-coated. In embodiments, the electrodes maybe disposed at a predetermined spacing for use in ECA. The system mayinclude a sensor that measures at least one of concentration and pH. Inembodiments, the control module may be programmed to reverse thepolarity of the electrodes after a pre-determined period of time. Inembodiments, the system may include an impeller for mixing the solution.The system may be powered by at least one of line power, a battery,solar energy and kinetic energy. In embodiments, the system may operateat less than or equal to 120 Volts or less than or equal to 240 Volts.The system may operate at 4 Amps, 8 Amps, or at least 10 Amps. Inembodiments, the time is at least one minute, at least five minutes, orat least ten minutes. The system may include a sensor which providesfeedback to the control module, wherein the control module modifiesoperation of the system based on the sensor feedback. The system mayinclude a user interface in communication with the control module,wherein the user interface is adapted to provide information about thestatus of at least one of the operation of the system and a condition ofthe solutions. The ECA product solution may be selected from the groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. An ECAproduct solution may be generated by the operation of the system and/orthe disclosed methods. The active species of the ECA product solutionmay be OH⁻. The system may include sale which is present in a traceamount.

The systems and methods disclosed herein may include a system comprisinga control module that controls the electrical operation of at least twoelectrodes, the at least two electrodes disposed at a distance from oneanother in communication with the control module, wherein uponapplication of electricity, a first electrode is adapted to bepositively charged and a second electrode is adapted to be negativelycharged, and a pump that is adapted to direct at least one of air orwater to the at least two electrodes, wherein the electrodes are adaptedto perform electrolysis of water containing trace quantities of salts.In embodiments the electrodes may be iridium-coated. In embodiments, thesystems and methods disclosed may comprise a cleaning solution generatedby operation of the system. The system may be powered by at least one ofline power, a battery, solar energy and kinetic energy. The system mayinclude a sensor that measures parameters of the water. In embodiments,the sensor may provide feedback to the control module, wherein thecontrol module modifies operation of the system based on the sensorfeedback. The system may include a user interface of in communicationwith the control module, wherein the user interface is adapted toprovide information about the status of at least one of the operation ofthe system and a condition of the solutions.

The systems and methods disclosed herein may include a system,comprising a control module that controls the electrical operation of atleast two electrodes the at least two electrodes disposed at a distancefrom one another in communication with the control module, wherein uponapplication of electricity, a first electrode is adapted to bepositively charged and a second electrode is adapted to be negativelycharged and a pump that directs at least one of air or water to the atleast two electrodes, wherein the electrodes are iridium-coated, andwherein the electrodes are adapted to perform ECA of a salt-containingsolution to produce an ECA product solution. In embodiments, the saltmay be sodium chloride, a mixture of sodium chloride and citric acid, orpotassium carbonate. The salt may also be present in a trace amount. Thesystem may be powered by at least one of line power, a battery, solarenergy and kinetic energy. The system may also include a sensor thatmeasures a condition of the salt-containing solution, wherein the sensorprovides feedback to the control module and wherein the control modulemodifies operation of the system based on the sensor feedback. Thesystem may include a user interface in communication with the controlmodule, wherein the user interface is adapted to provide informationabout the status of at least one of the operation of the system and acondition of the solutions. The distance between the at least twoelectrodes may be adjustable by at least one of a manual mechanism andan automatic mechanism. In embodiments, the distance between the atleast two electrodes may be adjustable in response to a measurement by asensor. The distance between the at least two electrodes may becontrolled by the control module. In embodiments, the ECA productsolution may be selected from the group comprising a sanitizingsolution, a disinfecting solution, a cleaning solution, a degreasingsolution, and an antimicrobial solution. The ECA product solution may begenerated by the operation of the system. The active species of the ECAproduct solution may include at least one of Cl⁻ and OH⁻.

The systems and methods disclosed herein may include an immersion devicefor immersion into a receptacle containing an aqueous metal halide saltsolution, comprising a submersible housing, at least two electrodesspaced apart from each other within the submersible housing, a base unitelectrically coupled to the electrodes to provide electricity to theelectrodes, wherein upon provision of electricity, electrochemicalactivation (ECA) of the aqueous metal halide salt solution in thereceptacle is caused to convert the solution in-situ into an ECA productsolution. In embodiments, the aqueous metal halide salt solution is asodium chloride (NaCl) solution. In embodiments, the distance betweenthe at least two electrodes is adjustable by at least one of a manualmechanism and an automatic mechanism. The distance between the at leasttwo electrodes may be adjustable in response to a measurement by asensor. The distance between the at least two electrodes may becontrolled by a control module in electrical communication with thedevice. The ECA product solution may be selected from the groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. Thesystems and methods disclosed herein may include the ECA productsolution generated by operation of the device. The active species of theECA product solution may be Cl⁻. In embodiments, the salt may be presentin a trace amount.

The systems and methods disclosed herein may include an immersion devicefor immersion into a receptacle containing an aqueous metal carbonatesalt solution, comprising, a submersible housing, at least twoelectrodes spaced apart from each other within the submersible housing,a base unit electrically coupled to the electrodes to provideelectricity to the electrodes, wherein upon provision of electricity,electrochemical activation (ECA) of the aqueous metal carbonate saltsolution in the receptacle is caused to convert the solution in-situinto an ECA product solution. The aqueous metal carbonate salt solutionis a potassium carbonate (K₂CO₃) solution. In embodiments, the distancebetween the at least two electrodes is adjustable by at least one of amanual mechanism and an automatic mechanism. The distance between the atleast two electrodes may be adjustable in response to a measurement by asensor. In embodiments, the distance between the at least two electrodesmay be controlled by a control module in electrical communication withthe device. The ECA product solution may be selected from the groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. Thesystems and methods disclosed herein, ECA product solution generated byoperation of the device. In embodiments, the active species may be OH⁻.In embodiments, the salt may be present in a trace amount.

A continuous flow system for creating an ECA product solution from asolution of water and a dissolved metal halide salt additive comprisingan intake that provides the water to the system, a source of additivethat provides metal halide salt to the water to create a solution, aflow conduit that directs the solution through the system, at least twoelectrodes in the flow conduit adapted to be in contact with thesolution, at least one flow control device in the flow conduit thatregulates flow through the flow conduit, and a controller coupled to theflow control device adapted to produce a continuous stream of ECAproduct solution. In embodiments, the system may include at least oneflow sensor that determines a flow rate of solution through the system.The system may include at least one chemical sensor that monitorschemical properties of the solution. In embodiments, the controller maybe further coupled to at least one flow sensor and at least one chemicalsensor to interactively provide power to the electrodes based uponreadings from the sensors. In embodiments, the flow control device maybe one of an intake valve and an outflow valve. In embodiments, the flowcontrol sensor may be one of an intake sensor and an outflow sensor. Inembodiments, the metal halide salt may be metal chloride salt or sodiumchloride (NaCl). In embodiments, the system may be adapted to providethe continuous stream in a hydraulic fracking application. Additionally,the system may be adapted to provide the continuous stream in at leastone of an airplane, a vehicle, a cruise ship, a humidifier, a vaporizer,a furnace, a floor scrubber, a warewashing facility, a laundry facility,a shower head, a faucet, a food sprayer, and a custodial sprayer. Inembodiments, the distance between the at least two electrodes may beadjustable by at least one of a manual mechanism and an automaticmechanism. In embodiments, the distance between the at least twoelectrodes may be adjustable in response to a measurement by a sensor.Additionally, the distance between the at least two electrodes may becontrolled by the controller. In embodiments, the ECA product solutionmay be selected from the group comprising a sanitizing solution, adisinfecting solution, a cleaning solution, a degreasing solution, andan antimicrobial solution. An ECA product solution may be generated bythe operation of the system and/or the disclosed methods. The activespecies of the ECA product may be Cl⁻. In embodiments, the salt may bepresent in a trace amount.

The systems and methods disclosed herein may include a continuous flowsystem for creating an ECA product solution from a solution of water anda dissolved metal carbonate salt additive comprising an intake thatprovides the water to the system, a source of additive that providesmetal carbonate salt to the water to create a solution, a flow conduitthat directs the solution through the system, at least two electrodes inthe flow conduit adapted to be in contact with the solution, at leastone flow control device in the flow conduit that regulates flow throughthe flow conduit, and a controller that operates the flow control deviceadapted to produce a continuous stream of the ECA product solution. Thesystem may include at least one flow sensor that determines a flow rateof solution through the system. The system may also include at least onechemical sensor that monitors chemical properties of the solution. Thecontroller may be further coupled to at least one flow sensor and atleast one chemical sensor to interactively provide power to theelectrodes based upon readings from the sensors. The flow control devicemay be one of an intake valve and an outflow valve. The flow controlsensor may be one of an intake sensor and an outflow sensor. Inembodiments, the metal carbonate salt may be potassium carbonate(K₂CO₃). The system may be adapted to provide the continuous stream in ahydraulic fracking application. The system may be adapted to provide thecontinuous stream in at least one of an airplane, a vehicle, a cruiseship, a humidifier, a vaporizer, a furnace, a floor scrubber, awarewashing facility, a laundry facility, a shower head, a faucet, afood sprayer, and a custodial sprayer. In embodiments, the distancebetween the at least two electrodes may be adjustable by at least one ofa manual mechanism and an automatic mechanism. In embodiments, thedistance between the at least two electrodes may be adjustable inresponse to a measurement by a sensor. In embodiments, the distancebetween the at least two electrodes may be controlled by the controller.The ECA product solution may be selected from the group comprising asanitizing solution, a disinfecting solution, a cleaning solution, adegreasing solution, and an antimicrobial solution. An ECA productsolution may be generated by the operation of the system and/or thedisclosed methods. The ECA product solution may include the activespecies OH⁻. In embodiments, the salt may be present in a trace amount.

The systems and methods disclosed herein may include a food treatmentsystem, comprising, at least two electrodes disposed at a distance fromone another in communication with a control module, wherein uponapplication of electricity, a first electrode may be adapted to bepositively charged and a second electrode is adapted to be negativelycharged the control module electrically coupled to the at least twoelectrodes, wherein the control module controls operation of the atleast two electrodes, and a pump that directs at least one of air,water, or a salt-containing solution to the at least two electrodes,wherein the electrodes are adapted to perform ECA of the salt-containingsolution to produce an ECA product solution, wherein the ECA productsolution is suitable for treating food. In embodiments, the salt may besodium chloride or a mixture of sodium chloride and citric acid. Thesystem may include a reservoir to collect the ECA product solution. Inembodiments, the salt may be present in a trace amount. The ECA productsolution may contain at least HOCl and may contain at least ionizedwater. In embodiments, the electrodes may be iridium-coated. The systemmay further include a spray nozzle to distribute the ECA productsolution from the system. In embodiments, the salt may be potassiumcarbonate. The ECA product solution may be selected from the groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. An ECAproduct solution may be generated by the operation of the system and/orthe disclosed methods. The active species of the ECA product may be OH⁻or Cl⁻.

The systems and methods disclosed herein may include a hand and skintreatment system, comprising at least two electrodes disposed at adistance from one another in communication with the control module,wherein a first electrode is adapted to be positively charged and asecond electrode is adapted to be negatively charged upon application ofelectricity, a control module electrically coupled to the at least twoelectrodes, wherein the control module controls operation of the atleast two electrodes, a pump that directs at least one of air, water, ora salt-containing solution to the at least two electrodes, wherein theelectrodes are adapted to perform ECA of the salt-containing solution toproduce an ECA product solution, wherein the ECA product solution issuitable for hand and skin treatment. In embodiments, the salt may besodium chloride or a mixture of sodium chloride and citric acid. Inembodiments, the system may include a reservoir to collect the ECAproduct solution. In embodiments, the salt may be present in a traceamount. In embodiments, the ECA product solution may contain at leastHOCl. In embodiments, the ECA product solution may contain at leastionized water. In embodiments, the electrodes may be iridium-coated. Inembodiments, the system may include a spray nozzle to distribute the ECAproduct solution from the system. In embodiments, the salt is potassiumcarbonate. The ECA product solution may be selected from the groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. An ECAproduct solution may be generated by the operation of the system and/orthe disclosed methods. The system may include the ECA product solutionwith active species OH⁻ or Cl⁻. In embodiments, the ECA product solutionmay be an emollient.

The systems and methods disclosed herein may include a surface treatmentsystem, comprising at least two electrodes disposed at a distance fromone another in communication with the control module, wherein a firstelectrode is adapted to be positively charged and a second electrode isadapted to be negatively charged upon application of electricity, acontrol module electrically coupled to the at least two electrodes,wherein the control module controls operation of the at least twoelectrodes and a pump that directs at least one of air, water, or asalt-containing solution to the at least two electrodes, wherein theelectrodes are adapted to perform ECA of the salt-containing solution toproduce an ECA product solution, wherein the ECA product solution issuitable for surface treatment. In embodiments, the salt may be sodiumchloride or a mixture of sodium chloride and citric acid. Inembodiments, the system may include a reservoir to collect the ECAproduct solution. In embodiments, the salt may be present in a traceamount. In embodiments, the ECA product solution may contains at leastHOCl or at least ionized water. The system may include electrodes whichare iridium-coated. Additionally, the system may further include a spraynozzle to distribute the ECA product solution from the system. Inembodiments, the system may include salt which is potassium carbonate.The ECA product solution may be selected from the group comprising asanitizing solution, a disinfecting solution, a cleaning solution, adegreasing solution, and an antimicrobial solution. An ECA productsolution may be generated by the operation of the system and/or thedisclosed methods. The ECA product solution may include an activespecies of OH⁻. The ECA product solution may include an active speciesCl⁻.

The systems and methods disclosed herein may include a method,comprising providing at least two electrodes adapted to be immersed inan aqueous salt solution each disposed at a distance from one another,wherein upon the application of electricity a first electrode is adaptedto be positively charged and a second electrode is adapted to benegatively charged and providing a control module electrically coupledto the electrodes, wherein the control module controls operation of theat least two electrodes and wherein the electrodes are coated withiridium wherein the control module may control the provision ofelectricity to the electrodes in a manner to perform ECA of the aqueoussalt solution to create an ECA product solution. In embodiments, themethod may generate an ECA product solution selected from a groupcomprising a sanitizing solution, a disinfecting solution, a cleaningsolution, a degreasing solution, and an antimicrobial solution. The saltmay be at least one of sodium chloride and a mixture of sodium chlorideand citric acid. The ECA product solution may contain at least HOCl. Thesalt may be at least potassium carbonate. The ECA product solution maycontain at least KOH. The salt may be present in a trace amount. The ECAproduct solution may contain at least ionized water. The method mayinclude using a spray nozzle to distribute the ECA product solution. Themethod may include using a reservoir to collect the ECA productsolution. The method may be adapted to provide ECA product solution in ahydraulic fracking application. In embodiments, the method may beadapted to provide ECA product solution in at least one of an airplane,a vehicle, a cruise ship, a humidifier, a vaporizer, a furnace, a floorscrubber, a warewashing facility, a laundry facility, a shower head, afaucet, a food sprayer, and a custodial sprayer. In embodiments, themethod may include using a control module programmed to reverse thepolarity of the electrodes after a pre-determined period of time.Additionally the method may include operating an impeller for mixing thesolution. The method may include utilizing power from at least one ofline power, a battery, solar energy and kinetic energy. The distancebetween the at least two electrodes may be adjustable by at least one ofa manual mechanism and an automatic mechanism. The distance between theat least two electrodes may be adjustable in response to a measurementby a sensor. The distance between the at least two electrodes may becontrolled by the control module. An ECA product solution generated bythe operation of the method may have active species of at least one ofOH⁻ and Cl⁻.

The systems and methods disclosed herein may include a method,comprising providing a portable receptacle adapted to contain an aqueoussolution of a carbonate salt, providing at least two electrodes spacedapart from each other within the portable receptacle, providing at leasttwo receptacle contacts being electrical contacts disposed on thecontainer, electrically connected to the electrodes; and providing abase adapted to receive the receptacle and provide electricity to thereceptacle contacts, wherein upon the provision of electricity to thereceptacle contacts, an electrochemical activation (ECA) of the aqueoussolution is caused in the portable receptacle to convert the aqueoussolution into an ECA product solution.

The systems and methods disclosed herein may include a method,comprising providing a portable receptacle adapted to contain an aqueoussolution of a halide salt, providing at least two electrodes spacedapart from each other within the portable receptacle, providing at leasttwo receptacle contacts being electrical contacts disposed on thecontainer, electrically connected to the electrodes, and providing abase adapted to receive the receptacle and provide electricity to thereceptacle contacts, wherein upon provision of electricity, anelectrochemical activation (ECA) of the aqueous solution in the portablereceptacle is caused to convert the aqueous solution into an ECA productsolution.

The systems and methods disclosed herein may include a method forcreating a cleaning solution comprising, providing a portable receptacleadapted to contain water, providing at least two electrodes spaced apartfrom each other within the portable receptacle, providing at least tworeceptacle contacts being electrical contacts disposed on the container,electrically connected to the electrodes, providing a base adapted toreceive the receptacle and provide electricity to the receptaclecontacts, wherein upon provision of electricity, ionization of the waterin the portable receptacle is caused to convert the water into acleaning solution.

The systems and methods disclosed herein may include a method forproviding an immersion wand device for immersion into a receptaclecontaining an aqueous carbonate salt solution, comprising providing anelongated housing having a handle at a first end and an immersion headat a second end, providing at least two electrodes spaced apart fromeach other within the immersion head, providing a base unit electricallycoupled to the electrodes to provide electricity to the electrodes,wherein upon provision of electricity, ECA of the aqueous carbonate saltsolution in the receptacle is caused to convert the solution in-situinto an ECA product solution.

The systems and methods disclosed herein may include a method forproviding an immersion wand device for immersion into a receptaclecontaining an aqueous metal halide salt solution, comprising, providingan elongated housing having a handle at a first end and an immersionhead at a second end, providing at least two electrodes spaced apartfrom each other within the immersion head, providing a base unitelectrically coupled to the electrodes to provide electricity to theelectrodes, wherein upon provision of electricity, ECA of the aqueousmetal halide salt solution in the receptacle is caused to convert thesolution in-situ into an ECA product solution.

The systems and methods disclosed herein may include a method forcreating an ECA product solution from an aqueous metal halide saltsolution comprising, providing at least two electrodes adapted to beimmersed in the aqueous metal halide salt solution each disposed at adistance from one another, wherein upon application of electricity, afirst electrode is adapted to be positively charged and a secondelectrode is adapted to be negatively charged, and providing a controlmodule electrically coupled to the electrodes, wherein the controlmodule controls operation of the at least two electrodes wherein thecontrol module controls the provision of electricity to the electrodesin a manner to perform ECA of the aqueous metal halide salt solution tocreate an ECA product solution.

The systems and methods disclosed herein may include a method forcreating an ECA product solution from an aqueous carbonate saltsolution, comprising providing at least two electrodes adapted to beimmersed in the aqueous carbonate solution each disposed at a distancefrom one another, wherein upon application of electricity, a firstelectrode is adapted to be positively charged and a second electrode isadapted to be negatively charged, and providing a control moduleelectrically coupled to the at least two electrodes, wherein the controlmodule controls operation of the at least two electrodes, wherein thecontrol module controls the provision of electricity to the electrodesin a manner to perform ECA of the aqueous carbonate solution to createan ECA product solution.

The systems and methods disclosed herein may include a method,comprising, providing a control module that controls the electricaloperation of at least two electrodes, the at least two electrodesdisposed at a distance from one another in communication with thecontrol module, wherein upon application of electricity, a firstelectrode is adapted to be positively charged and a second electrode isadapted to be negatively charged, and providing a pump that is adaptedto direct at least one of air or water to the at least two electrodes,wherein the electrodes are adapted to perform electrolysis of watercontaining trace quantities of salts.

The systems and methods disclosed herein may include a method comprisingproviding a control module that controls the electrical operation of atleast two electrodes, the at least two electrodes disposed at a distancefrom one another in communication with the control module, wherein uponapplication of electricity, a first electrode is adapted to bepositively charged and a second electrode is adapted to be negativelycharged, and providing a pump that directs at least one of air or waterto the at least two electrodes, wherein the electrodes areiridium-coated, and wherein the electrodes are adapted to perform ECA ofa salt-containing solution to produce an ECA product solution.

The systems and methods disclosed herein may include a method for animmersion device for immersion into a receptacle containing an aqueousmetal halide salt solution, comprising, providing a submersible housing,providing at least two electrodes spaced apart from each other withinthe submersible housing, providing a base unit electrically coupled tothe electrodes to provide electricity to the electrodes, wherein uponprovision of electricity, electrochemical activation (ECA) of theaqueous metal halide salt solution in the receptacle is caused toconvert the solution in-situ into an ECA product solution.

The systems and methods disclosed herein may include a method for animmersion device for immersion into a receptacle containing an aqueousmetal carbonate salt solution, comprising, providing a submersiblehousing, providing at least two electrodes spaced apart from each otherwithin the submersible housing, providing a base unit electricallycoupled to the electrodes to provide electricity to the electrodes,wherein upon provision of electricity, electrochemical activation (ECA)of the aqueous metal carbonate salt solution in the receptacle is causedto convert the solution in-situ into an ECA product solution.

The systems and methods disclosed herein may include a continuous flowmethod for creating an ECA product solution from a solution of water anda dissolved metal halide salt additive comprising, providing an intakethat provides the water to the system, providing a source of additivethat provides metal halide salt to the water to create a solution,providing a flow conduit that directs the solution through the system,providing at least two electrodes in the flow conduit adapted to be incontact with the solution, providing at least one flow control device inthe flow conduit that regulates flow through the flow conduit, andproviding a controller coupled to the flow control device adapted toproduce a continuous stream of ECA product solution.

The systems and methods disclosed herein may include a continuous flowmethod for creating an ECA product solution from a solution of water anda dissolved metal carbonate salt additive comprising, providing anintake that provides the water to the system, providing a source ofadditive that provides metal carbonate salt to the water to create asolution, providing a flow conduit that directs the solution through thesystem, providing at least two electrodes in the flow conduit adapted tobe in contact with the solution, providing at least one flow controldevice in the flow conduit that regulates flow through the flow conduit,and providing a controller that operates the flow control device adaptedto produce a continuous stream of the ECA product solution.

The systems and methods disclosed herein may include a food treatmentmethod, comprising providing at least two electrodes disposed at adistance from one another in communication with a control module,wherein upon application of electricity, a first electrode is adapted tobe positively charged and a second electrode is adapted to be negativelycharged;, providing the control module electrically coupled to the atleast two electrodes, wherein the control module controls operation ofthe at least two electrodes, and providing a pump that directs at leastone of air, water, or a salt-containing solution to the at least twoelectrodes, wherein the electrodes are adapted to perform ECA of thesalt-containing solution to produce an ECA product solution, wherein theECA product solution is suitable for treating food.

The systems and methods disclosed herein may include a hand and skintreatment method, comprising, providing at least two electrodes disposedat a distance from one another in communication with the control module,wherein a first electrode is adapted to be positively charged and asecond electrode is adapted to be negatively charged upon application ofelectricity, providing a control module electrically coupled to the atleast two electrodes, wherein the control module controls operation ofthe at least two electrodes and providing a pump that directs at leastone of air, water, or a salt-containing solution to the at least twoelectrodes, wherein the electrodes are adapted to perform ECA of thesalt-containing solution to produce an ECA product solution, wherein theECA product solution is suitable for hand and skin treatment.

The systems and methods disclosed herein may include a surface treatmentmethod, comprising providing at least two electrodes disposed at adistance from one another in communication with the control module,wherein a first electrode is adapted to be positively charged and asecond electrode is adapted to be negatively charged upon application ofelectricity, providing a control module electrically coupled to the atleast two electrodes, wherein the control module controls operation ofthe at least two electrodes, and providing a pump that directs at leastone of air, water, or a salt-containing solution to the at least twoelectrodes, wherein the electrodes are adapted to perform ECA of thesalt-containing solution to produce an ECA product solution, wherein theECA product solution is suitable for surface treatment.

These and other systems, methods, objects, features, and advantages ofthe present invention will be apparent to those skilled in the art fromthe following detailed description of the preferred embodiment and thedrawings.

All documents mentioned herein are hereby incorporated in their entiretyby reference. References to items in the singular should be understoodto include items in the plural, and vice versa, unless explicitly statedotherwise or clear from the text. Grammatical conjunctions are intendedto express any and all disjunctive and conjunctive combinations ofconjoined clauses, sentences, words, and the like, unless otherwisestated or clear from the context. Titles and headings have been addedsolely for the convenience of the reader and are not intended to limitor reduce the coverage of the descriptions.

BRIEF DESCRIPTION OF THE FIGURES

The invention and the following detailed description of certainembodiments thereof may be understood by reference to the followingfigures:

FIG. 1 depicts a block diagram of an ECA system.

FIG. 2 depicts embodiments of electrodes useful in an ECA system.

FIG. 3 depicts an elevational view of an embodiment as it would appearin use.

FIG. 4 depicts an elevational view of the immersion wand of FIG. 3 withstabilizer assembly.

FIG. 5 shows the inside chamber of the immersion head 300.

FIG. 6 shows an alternative embodiment of an immersion wand.

FIG. 7 depicts an elevational view of another embodiment, showing afirst alternative handle design.

FIG. 8 depicts an elevational view of another embodiment, showing asecond alternative handle design.

FIG. 8A depicts a perspective view of another embodiment, showing anextendable immersion head design.

FIG. 8B depicts a perspective view of another embodiment of theimmersion heads.

FIG. 8C depicts a view of the immersion head design of FIG. 9B with thetop housing removed.

FIG. 8D depicts an exploded view of the immersion head of FIG. 9B.

FIG. 9 depicts an enlarged view of the top of the handle 100 of theimmersion wand.

FIG. 10 depicts an enlarged view of the base unit 500.

FIG. 10A depicts another embodiment of a base unit 500.

FIG. 11A depicts an elevational view of another embodiment.

FIG. 11B depicts a plan view of the embodiment shown in FIG. 11A.

FIG. 11C depicts a perspective view of another embodiment similar tothat shown in FIGS. 11A and 11B.

FIG. 12 depicts a schematic diagram of an electrode-integratedreceptacle apparatus.

FIG. 12A depicts a perspective view of an embodiment consistent with theschematic of FIG. 12.

FIG. 12B depicts a perspective view of the receptacle of the embodimentshown in FIG. 12A.

FIG. 12C depicts a perspective view of the charging base receptacle ofthe embodiment shown in FIG. 12A.

FIG. 12D depicts a plan view of the bottom of the receptacle of FIG.12B.

FIG. 12E depicts a sectional view of the receptacle of FIG. 13B viewingthe bottom of the receptacle.

FIG. 12F depicts an exploded view of the receptacle apparatus of FIG.12A.

FIG. 12G depicts an exploded view of another receptacle embodiment.

FIG. 13 depicts an instant flow apparatus.

FIG. 13A depicts a front elevational view of the apparatus of FIG. 13.

FIG. 13B depicts a rear elevational view of the apparatus of FIG. 13with the cover removed.

FIG. 13C depicts another rear elevational view of the apparatus of FIG.13 with the cover removed.

FIG. 13D depicts a pie chart illustrating an example of the compositionof fracking fluids.

FIG. 13E depicts a continuous flow apparatus for use in the frackingindustry.

FIG. 13F depicts an exploded view of an alternative embodiment of aninstant flow apparatus.

FIG. 13G is an enlarged view of elements of the instant flow apparatusof FIG. 13F.

FIG. 13H is an enlarged view of elements of the instant flow apparatusof FIG. 13F.

FIG. 13I is an enlarged view of elements of the instant flow apparatusof FIG. 13F.

FIG. 13J depicts an exploded view of an alternative embodiment of aninstant flow apparatus, showing the system electronics.

FIG. 13K depicts an exploded view of the front panel of an alternativeembodiment of an instant flow apparatus.

FIG. 14 is a table showing various parameters for use of certainembodiments.

DETAILED DESCRIPTION

By applying an electric current to a solution of water and common salts,an electrolysis of the salts in solution occurs, which is known aselectrochemical activation or “ECA”. Depending on the salt, variousproducts and active species can be generated via ECA. In the prior art,the current was delivered to the solution via an anode and a cathode toproduce an electrolyte solution that was separated into both an anolyteand a catholyte. Such separation required various technologies, such asmembranes, receptacles, and the like, to separate the anolyte from thecatholyte. While delivering electrical current to the solution via ananode and a cathode, the instant application discloses systems andmethods of ECA that do not require the separation of the resultant ECAproduct solution. The instant application discloses a variety ofapparati, including embodiments that are handheld, tabletop,wall-mounted, bath, sprayer, floor scrubber, device integrated and manyothers, for ECA where the salt-containing solution interacts with theelectrodes to produce an ECA product solution in a blended stream.Certain of these embodiments are sized to enable portability and/or easydeployment. Certain embodiments are battery-powered to enableportability and various applications where other power sources are notreadily available. The ECA product may be environmentally safe cleaners,sanitizers, disinfectants, antimicrobials, degreasers and the like.Further, the instant application discloses various reactants to be usedin ECA. One reactant is a sodium chloride (NaCl) and citric acid(C₆H₈O₇) mixture wherein ECA produces a product comprising ahypochlorous acid (HOCl) solution that exhibits a shelf life of up to 60days, a pH in the range of about 3-7 and a free available chlorineconcentration (FAC) of about 20 ppm to 1000 ppm. Another reactant ispotassium carbonate (K₂CO₃) wherein ECA produces a product comprising apotassium hydroxide (KOH) solution. In any event, the pH of ECA productsolutions produced may range from pH 2 to a high of pH 12. The pH may belower or higher in certain embodiments. These apparatus, solutions andtheir various designs and uses are further described herein.

Referring now to FIG. 1, a block diagram depicting the variouscomponents of an embodiment of an ECA system 1000 as described herein isshown. The ECA system 1000 may include at least two electrodes 1004 butcan include more than two in various embodiments, as described herein. Acontrol module 1010 may include a processor 1024 and the necessarymemory, programs and logic to control the system. The control module1010 may provide current to the electrodes 1004 as described herein ormay control the current provided by the power source 1018. When thecontrol module 1010 provides a DC current to the electrodes 1004, oneelectrode 1004 may become positively charged while the other electrode1004 may be negatively charged, depending on the current flow. In thisway, the electrodes 1004 form an anode (the negatively charged electrode1004) and a cathode (the positively charged electrode 1004). Whenelectrodes 1004 are placed in a liquid, such as water or a saltsolution, the electrodes cause an electrolysis reaction in the water orsalt solution. The products of the reaction may be allowed to blend asthey are formed and as they remain in solution. These reactions aredescribed herein. As shown in FIG. 1 and described in more detailherein, the ECA system 1000 may further include a water pump 1008,impeller 1020, sensor 1022, air pump 1012 and reservoir 1014.

The conductivity of the solution is based upon the amount of dissolvedparticles in the solution. In a high concentration, the water is veryconductive. In a low concentration, the water is less conductive. Lowconductivity allows for slower electro-chemical reactions but has lessenergy dissipated. High conductivity allows for faster electro-chemicalreactions, but draws a great deal of power. The amount of powerdissipated can cause the electrodes, or system electronics to overheatand to become damaged. Therefore, the spacing between the electrodes isimportant, as well as the power and duration of the power to provide tothe electrodes. A further discussion is provided herein.

The electrodes 1004 may be disposed at a particular distance from oneanother. The distance between surfaces of the electrodes 1004 may beselected to optimize the operation of the electrodes 1004. For example,the distance may be about 8 mm. In some embodiments, the distance may beless than 8 mm, while in other embodiments the distance may be greaterthan 8 mm. In any event, the distance may be modified to improve oralter the operation of the electrodes 1004. The electrodes may bemounted on a rack or other attachment system that allows for movementalong a continuous path or a path that is limited to obtain setelectrode spacing. In other embodiments, the electrodes may be attachedat discrete attachment points and the electrodes can be moved betweenvarious attachment points to obtain different spacing.

The distance between electrodes may be adjusted manually, automatically,or in response to sensor feedback, such as for example to operate thesystem with different concentrations of salts, and with different powersettings. For example, the electrodes may be automatically adjusted suchas when a user inputs a parameter to the system and the optimalelectrode distance based on the parameter is different from the currentsetting. In an embodiment, the distance between the electrodes may beadjusted in response to sensor feedback. For example, as theconcentration of HOCl increases as ECA proceeds, the resistance of thesolution also increases. A sensor may measure the concentration of FAC,the temperature of the electrodes and/or the resistance of the solutionand make an adjustment in the distance of the electrodes in response tothe measurement. By making this sensor-based adjustment, the spacing ofthe electrodes may be kept optimal, such as to keep the temperature inthe electrodes from becoming too high. In embodiments, automatic andsensor-based electrode adjustment may be controlled by the controlmodule 1010. In embodiments, while electrodes may generally be disposedin parallel to one another, in other embodiments, electrodes may bedisposed at an angle with respect to one another. If the electrodes wereangled with respect to each other, most of the current flow would occurwhere the electrodes are the closest. This may result in uneven reactionrates that may take longer to create a uniform solution. However, asconditions change in the ECA product solution, certain portions of theelectrodes may be optimally spaced due to the angling. Indeed, asconditions continue to change in the ECA product solution, otherportions of the electrodes may be optimally spaced. By angling theelectrodes with respect to one another, the electrodes may on averagefunction well enough, but the range of spacing between the electrodesmay be optimal for conditions throughout the reaction.

If it is assumed that the concentration is higher in one location asopposed to other locations, it may be beneficial to adjust the distancesbetween the electrodes accordingly.

Consider, for example, an embodiment where there are three electrodesarranged horizontally parallel to each other each higher that the last.In this embodiment, the top and bottom electrodes would both be eitheranodes or cathodes with the middle electrode being the oppositepolarity. If salt is dropped in the container at the bottom, it has itshighest concentration at the bottom with lower concentrations as onemoves vertically upward. Therefore, for uniform reactions, one shouldhave the spacing between the lowest and middle electrodes being largerthan the spacing between the top and middle electrodes. The differenceswould be based upon the relative differences in the concentrationbetween each pair of electrodes. In other embodiments, the oppositespacing may be present.

In embodiments, at least two electrodes may be needed by the ECA system1000. In embodiments, more than two electrodes may be employed by thesystem. For example, electrodes may operate in pairs, however, the pairsmay utilize shared electrodes. For example, an ECA system 1000 mayutilize three electrodes. In this configuration, two of the electrodesmay be positively charged and one of the electrodes may be negativelycharged. The negatively charged electrode may be shared electrode sothat two pairs of electrodes are formed in this configuration. When thepolarity is reversed in this configuration, only one of the electrodesis positively charged while two of the electrodes are negatively chargedand the positively charged electrode is the shared electrode. Inembodiments, certain embodiments of the ECA system 1000 may use arraysof a plurality of electrodes, such as might be useful in large scaleapplications of the ECA system 1000.

In embodiments, the electrodes 1004 may be sized and shaped forparticular embodiments and applications of the ECA system 1000. Forexample, the electrodes 1004 may be in a generally round shape, in agenerally rectangular shape, in a generally square shape, or in anyother shape or geometry that is conducive to operation as electrodes inthe system. For example, FIG. 2 depicts several embodiments ofelectrodes 1004 in different shapes. Electrode 1100 is shaped in agenerally rectangular shape. In certain embodiments, such as in anelongated immersive apparatus embodiment such as that shown in FIGS. 3,4, 7, 8, and 8A, two or more electrodes 1100 may be disposed adjacent toone another in operation. The generally rectangular shape is conduciveto being disposed within the generally elongated apparatus. Electrode1102 is shaped in a generally circular shape.

The environment in which the electrodes operate is harsh and corrosiveto metals. Applying electric current to the electrodes further promotescorrosion. The electrical conductivity of the electrodes decreases asthe electrodes become corroded. This causes them to operate in a lessefficient manner. The electrodes also tend to warp and lose structuralintegrity as they corrode. This leads to misaligned electrodes orelectrodes that may touch each other and short circuit. Therefore, it isnecessary to use materials that both conduct electricity well, and donot corrode.

In an embodiment, the electrodes may include pure forms, oxides oralloys of various metals, such as platinum, titanium, iridium and thelike. Other materials are also contemplated for use in electrodes, suchas various metals, graphite, and semiconductors.

For example, an embodiment of an electrode 1004 used in the ECA system1000 is a chip containing an alloy of platinum and titanium coated withpure iridium. In another example, an embodiment of an electrode 1004used in the ECA system 1000 is a chip containing an alloy of platinumand titanium coated with iridium oxide. In yet another example, anelectrode 1004 for use in the ECA system 1000 may be a pure iridium oran iridium oxide electrode.

The iridium coating increases the efficiency with which current ispassed through the water or solution. Iridium is a more effectiveconductor and is substantially resistant to corrosion.

In embodiments, the electrodes 1004 are in communication with thecontrol module 1010. The control module 1010 controls the operation ofthe electrodes 1004 to perform electrolysis of the components of thewater or solution that is in contact with the electrodes 1004. Thecontrol module 1010 delivers or controls the delivery of current to theelectrodes to maintain either a positive or a negative charge on eachelectrode 1004. The control module 1010 may include a processor 1024that has the necessary hardware and software to sense conditionsdirectly or based on input from separate sensors, determine actions andoperate the system. In other embodiments, the control module 1010 mayinclude a processor 1024 in communication with external sensors, whereinthe processor processes sensor measurements in order to determineconditions, determine actions, and operate the system. The controlmodule 1010 is adapted to control the delivery of current in timedpatterns, to modify the voltage, to reverse or modify the polarity, tochange the current flowing to the electrodes, to control the speed offlow of water or solution into or through the ECA system, to control thespeed of an impeller, and the like.

The control module 1010 can be programmed to control delivery of thecurrent to the electrodes 1004 in a timed fashion. In embodiments, thetiming may be selected to generate a particular level of FAC in solutionor concentration of another active species, to obtain a particular pHlevel, to obtain a particular molarity/concentration of products insolution, to obtain completion of a chemical reaction, and the like. Insome embodiments, the control module 1010 may deliver current for aperiod of at least one minute, at least two minutes, at least threeminutes, at least four minutes, at least five minutes, at least tenminutes, and the like. In some embodiments, the control module 1010 canbe programmed to operate the electrodes 1004 continuously. The controlmodule 1010 may cause the ECA system 1000 to operate for a specificamount of time to deliver a specific amount of electrical energy to theelectrodes 1004. The control module 1010 may cause the ECA system 1000to operate for a specific amount of time to deliver a specific amount ofelectrical energy to the electrodes 1004 to achieve a specific level ofFAC or concentration of another active species. In embodiments, the FACor concentration of another active species may be determined by a sensor1022 that feeds back information to the control module 1010 such as tocause operation of the electrodes 1004 to stop when reaching aparticular FAC or concentration of another active species or continue ifan FAC or concentration of another active species has not been reached.Varying the operation time of the electrodes 1004 of the ECA system 1000may vary one or more of the products and the concentration of theproducts in solution after operation of the electrodes 1004.

In an embodiment, the control module 1010 can be programmed to alter thecurrent delivered to the electrodes 1004. Dissolved materials in thewater migrate to various electrodes based upon their polarity. Forexample positively charged calcium ions are drawn toward the anode. Overtime, there is a calcium accumulation. In order to minimize this effect,the control module 1010 reverses the polarity of the current provided tothe electrodes 1004. In an embodiment, the control module 1010 may beprogrammed to reverse the polarity of the electrodes 1004 duringoperation. For example, if the cycle time is 5 minutes, the controlmodule 1010 may be programmed to reverse the polarity of the electrodesat the 2.5 minute mark, or halfway through the cycle. In anotherembodiment, the control module 1010 may be programmed to reverse thepolarity of the electrodes at pre-determined intervals during operation.For example, upon the completion of each two minute period, the controlmodule 1010 may reverse the polarity of the electrodes 1004. In yetanother embodiment, the control module 1010 may be programmed to pauseoperation for a pre-determined period of time during operation. Forexample, the control module 1010 may be programmed to pause for thirtyseconds for every two minutes of operation. In certain embodiments, thepause feature may be combined with the polarity reversal feature. Forexample, the current delivery may be paused for thirty seconds after twominutes of operation then the polarity may be reversed when operationcommences. Reversing the polarity of the electrodes may result inimproved electrode operation, such as by limiting calcification of theelectrodes.

In an embodiment, the control module 1010 may support operation of theECA system 1000 at less than or equal to 120 volts or at less than orequal to 240 volts or in other embodiments at higher voltages. In anembodiment, the control module 1010 may support operation of the ECAsystem 1000 at variable amperage, such as 4 amps, 8 amps, 10 amps, 17amps, and the like. The amperage may be selected for optimum operationof particular embodiments of the ECA system 1000. For example, while theelongated immersive apparatus may be operated at amperages between 8 and15, certain versions of the electrode-integrated receptacle apparatusare operated at only 4 amps. Further details of the amperages at use invarious embodiments of the ECA system 1000 are further described herein.In some embodiments, the AC current is converted to DC.

In an embodiment of the current invention, the control module 1010operates to sense various conditions of the system through sensors 1022.For example, a sensor located near the electrodes 1004 may monitor thetemperature of the electrodes 1004. During high current flow, these canreach a temperature which may damage the electrodes 1004. The controlmodule 1010 may then reduce the current provided to the electrodes 1004or stop the current flow until they cool off to an operatingtemperature.

As indicated above, the control module 1010 may also monitor a sensor1022 that measures the concentration of the product or active species.It may operate or continue operation of the device until the amount ofan active species is reached. It may also increase power provided to theelectrodes to increase the measured active species amount if it is belowa desired amount. Sensors 1022 external or internal to the ECA systemmay be adapted to measure pH, concentration (in ppm or FAC), oxygenlevels, voltage, resistance, temperature, fluid level, and the like.

The control module may also have an internal logic in the form of aprogram or other executable commands that would determine if the ECAsystem may not reach its desired goal of a programmed FAC level. Forexample, it may have a timeout trigger that monitors the amount of powerprovided and the change in FAC over a period of time. If it appears thatit is not possible to reach the FAC goal within a predetermined amountof time, it will indicate an error reading or other message to the user.This is useful in the case where there is not enough reactant providedto the solution. The control module may be adapted to detect othererrors, such as incorrect reactants added to a starting solution, excessreactants added in solution, incorrect reaction conditions, incorrectoutputs, early reaction completion as determined by measurement of theECA product solution or other factors, and the like. For example, ifexcess reactants are detected, current may be barred from flowing to theelectrodes or the amount of current may be increased. Error detectionmay be aided or enabled by the use of sensors 1022 that feedback to thecontrol module 1010.

The control module 1010 may have an internal logic to determine when toomuch or too little power is being used by the electrodes. A shortcircuit will draw a great deal of current. The control module 1010 willsense this draw, such as by an internal or external sensor 1022 thatmonitors current provided to the electrodes, and shut down the device.

In another situation, there may be no solution between the electrodes.In this case, the control module 1010 may determine, such as byreceiving feedback from a fluid sensor that there is no fluid betweenthe electrodes or by monitoring the activity of the electrodes that nocurrent is being drawn by the electrodes, and shut down the power or notdeliver current to the electrodes in the first place.

The control module 1010 may include integrators and clocks to perform asummation/integration of the current provided over time and use this tomake decisions. It may also perform an integration/summation of thepower dissipated over a period of time, again to make determinations. Itmay also calculate and provide information on the FAC or concentrationof another active species for given periods of time, the periods of timethat the unit was operational/non-operational, error reports and otherreports.

Embodiments of the ECA system may include a user interface, such as todisplay visual information or provide audio or electronic informationregarding the operation of the system. For example, a display screen mayprovide the FAC or concentration of another active species, the amountof reactants present or a measure of the elapsed time from starting aparticular action or the time to completion of an action or attaining aparticular objective. For example, a visual indicator of the userinterface may display information regarding the polarity of theelectrodes. In the example, when the polarity of the electrodes is in aparticular configuration, particular colors or icons may be displayed oranimated. When the polarity changes, the visual indicator may becomealtered to indicate the change in polarity. In a further example, thepolarity indicator may be a light or icon that is operated in a firstpattern when the current is being applied in a first polarity and asecond pattern when the current is being provided in a second polarity.In this embodiment, the lights are in a circular pattern. The lights arelit in a circular pattern in a clockwise direction when it is operatingin a first polarity and in a counterclockwise direction when it isoperating in a second polarity. In another example, the user interfacemay provide alerts or information, either visually or in audio, to auser of the ECA system. Such an alert may indicate a pause in thesystem, a termination of a programmed time of operation, commencement ofoperation, and the like. Alerts may be tied to sensor operation. Forexample, a sensor may measure a scarcity of reactants and feedback theinformation to a control module 1010 in order to generate an alert to auser indicating the scarcity. In another example, a sensor may measurethe pH and feedback the information to a control module 1010 in order togenerate an alert to a user indicating the pH. In other embodiments,such as large scale operations, messages may be generated and displayedor delivered to a user of the system. All information pertaining tooperation of the system and its components may be displayed or otherwiseprovided by a user interface of the system.

In embodiments, the ECA system 1000 may optionally include a pump. Thepump may be an air pump 1012 that directs air through the housing 1002to support the flow of water or solution through the housing 1002. Anair pump 1012 may be useful when the ECA system 1000 is embodied as anelongated immersive apparatus, referred to as the Immerse-A-Clean™ Wanddesign, as any other immersive apparatus, such as the immersion diskdesign or as an electrode-integrated portable receptacle design,referred to as the “Trio™”, a Medical Receptacle Design referred to asthe “Trio Rx™” design and an Enlarged Receptacle Design referred to as“Trio Maxx™”. The pump may be a water pump 1008 to direct water or asalt-containing solution to the at least two electrodes 1004. A waterpump 1008 may be useful in any apparatus embodying the ECA system 1000.The air pump 1012 or water pump 1008 may be under the control of thecontrol module 1010. For example, the pumps 1008, 1012 may engage for aperiod of time prior to activation of the electrodes 1004 to provideagitation for proper mixing of the reactants in solution. In anotherexample, the pumps 1008, 1012 are controlled to vary the speed of flowof the water or the solution. In other embodiments, the pumps 1008, 1012may pump reactants.

In an embodiment, an optional impeller 1020 may be included in the ECAsystem 1000. Certain embodiments of the ECA system 1000, such as theelongated immersive apparatus, may include an impeller 1020 within thehousing 1002 to mix solution contained within the housing 1002.Alternatively, the impeller 1020 may be mounted on an end of, on asurface of, or around the housing 1002 to agitate the solution in whichthe apparatus is immersed. In other embodiments, such as anelectrode-integrated portable receptacle designs, the impeller 1020 maybe disposed in a lower portion of the receptacle. The impeller 1020 maybe removably connected. In some embodiments, the impeller 1020 mayoperate using magnetic forces. The impeller 1020 may be under thecontrol of the control module 1010. For example, the control module 1010may time the operation of the impeller 1020 so that the impeller 1020operates for a sufficient amount of time to ensure the adequate mixingof the reactants into solution prior to commencing electrode 1004activation.

In an embodiment, the ECA system 1000 may be powered by various powersources 1018. For example, the ECA system 1000 may operate on analternating current power supply. The power can be supplied at variousvoltages between 110 volts and 240 volts or other voltages. All of theembodiments described herein may work with standard household voltage of120/240 VAC. The 110 volt power may be stepped down to 12 volts (orother voltages) for safety or other reasons, to power devices embodyingthe system, and/or charge the system battery. The ECA system 1000 mayoperate on a car charger, an external battery pack, a wall plug, and thelike. A power cord of the ECA system 1000 may be adapted to terminate ina way to facilitate receiving power from many different sources. Forexample, in FIG. 8A, a USB cord 470 connects a control module/air pump472 of the immersive wand to either a 110 V wall plug 474, a 12V carcharger 478, or a battery pack 480. The ECA system 1000 may operate onsolar energy. For example, a component of the ECA system 1000 itself,such as the housing 1002 or the control module 1010, may support a solarcell for collecting solar energy. Appropriate electronics for convertingthe solar energy for use in the ECA system 1000 may be included in theECA system 1000, such as in the control module 1010. In certainembodiments, the ECA system 1000 may operate on battery power, such ason a 12 volt battery. The battery may be a part of the ECA system or maybe part a device into which the ECA system is integrated. The powersource may include a 12 volt converter attached to certain equipment.The battery may be rechargeable or disposable. In other embodiments, theECA system 1000 may be powered by using kinetic energy harnessed by agenerator of the ECA system 1000. For example, a hand crank generatormay be disposed on the elongated immersive apparatus or on its controlmodule 1010 or otherwise in electrical communication with the apparatusor components thereof. For example, the kinetic energy may result fromthe cleaning motion of the device, for example, as a result of a userusing the device. In another example, the ECA system embodied in or as afloor scrubber may be powered by the kinetic energy generated frommoving the floor scrubber. In embodiments, power may be supplied as analternating current (AC) or in other embodiments as direct current (DC).In other embodiments, the power supplied as AC may first be converted toDC before its use in the ECA system. Embodiments of the ECA system mayinclude quick-connect battery terminals for powered cleaning equipment.Embodiments of the ECA system may include an on-board ground faultcircuit interrupter (GFCI) or other GFCI technology. In embodiments, theECA system, possibly the power source, may include one or more fuses.

In an embodiment, the ECA system 1000 may optionally include one or moresensors 1022. The sensor 1022 may be adapted to determine any of pH,FAC/ppm, Cl⁻ amounts, OH⁻ amounts, oxygen amounts, ion amounts,temperature, alkalinity, acidity, particulate level, pathogen level,volume, pressure, fluid presence/moisture, specific reactants, specificactive species, voltage, current, resistance and the like. Sensor 1022feedback to a control module 1010 of the ECA system 1000 may cause achange in control of a parameter of the ECA system 1000. For example, ifthe sensor 1022 determines that a particular pH has been reached insolution, the control module 1010 may use the sensor 1022 reading as anindication that electrode 1004 activation should terminate.

In the embodiment employing continuous flow, sensors 1022 are includedthat may monitor the rate of input flow, the reservoir fluid level, therate of output fluid flow and the like. It may also measureconcentrations of various chemical entities entering the system, in itsreservoir and exiting the system. The sensors 1022 may determine handofffrom one component of the system to another.

A sensor 1022 may be a voltmeter or over-volt meter or multi-meter toindicate how much voltage or current is being applied to or across theelectrodes. The voltmeter can tie in to an auto safety shut off.Feedback from the voltmeter may cause a user to vary a setting of thesystem, such as the amperage.

The ECA system 1000 may include a reservoir 1014 in various embodiments.For example, the reservoir 1014 may be a receptacle exterior to the ECAsystem 1000 into which the ECA product solution may flow, such as whenthe ECA system 1000 is embodied in an instant flow apparatus, which isdescribed herein. In another example, the reservoir 1014 may be areceptacle exterior to the ECA system 1000 into which an apparatusembodying the system, such as an immersive apparatus, may be placed. Inthis example, the reactants may be placed in solution in the reservoir1014 and at least a portion of the immersive apparatus may be placedinto the reservoir 1014 containing the reactant solution. In yet otherembodiments, such as when the ECA system 1000 is embodied in anelectrode-integrated receptacle apparatus, the reservoir 1014 may be thereceptacle itself. The electrodes 1004 are constantly exposed tosolution in the reservoir 1014 as they are integrated into thereceptacle.

The ECA system 1000 may enable various salt-mediated electrolysisreactions to electrochemically activate water. In embodiments, the saltsmay be present in trace amounts in a municipal water supply. In otherembodiments, the salts may be added to a reactant solution as thereaction proceeds. In any event, solutions produced by the ECA system1000 may be useful for sanitization, disinfecting, antimicrobialapplications, aseptic applications, cleaning, and the like, as furtherdescribed herein. According to the FDA, “sanitization” means theapplication of cumulative heat or chemicals on cleaned food-contactsurfaces that, when evaluated for efficacy, is sufficient to yield areduction of 5 logs, which is equal to a 99.999% reduction, ofrepresentative disease microorganisms of public health importance.Typically, sanitizing solutions are regulated by law in accordance with21 CFR 178.1010 to provide not more than 200 ppm of available halogendetermined as FAC. US FIFRA Act 7 U.S.C. Section 136g (C)(3) Section12(a)(1)(A) governs the designation of disinfectants that containgreater than 200 ppm. In certain embodiments herein, the terms sanitizerand disinfectant may have these meanings.

In one example, the starting material for the ECA system 1000 is amixture of sodium chloride and citric acid. In an embodiment, the citricacid is blended with the sodium chloride in a ratio sufficient tosupport a buffering reaction in the ECA product solution and prevent thepH from being too low or too high. In embodiments, the pH of the HOClECA product solution is maintained between pH 5.5 and pH 7.2 by thebuffering reaction. In an embodiment, the ratio is 96% NaCl to 4% citricacid. For example, as the ECA production solution acidifies, Cl₂ maybubble out of solution and lower the FAC concentration. When thesolution of sodium chloride and citric acid is exposed to the electrodesof the ECA system 1000, an electrolysis reaction occurs. Electrolysis ofthe sodium chloride may produce at least hypochlorous acid, which is amild acid that, depending on the circumstances, has sanitizingproperties, disinfectant properties, antimicrobial properties and thelike. Other chloride containing species are also possible products ofthe electrolysis reaction. Further, sodium hydroxide (NaOH) may beproduced by the electrolysis reaction. Various other components andgases may also be produced by the electrolysis reaction, such aschlorine gas (Cl₂), hydrogen gas (H₂), oxygen (O₂), and, when waterionizes, ozone (O₃). Ozone itself may act as an antimicrobial and/ordisinfectant. In embodiments, the oxygen being released may saturate theaqueous solution so that it may act as an antimicrobial agent.

In certain embodiments, the reactant salt is sodium chloride alonewithout any citric acid.

The product solution of hypochlorous acid may exhibit a pH in the rangeof 3 to 7. In certain embodiments, the ECA product solution ofhypochlorous acid may exhibit a pH in the range of 5-7. In embodiments,the relative concentration of NaOH and HOCl in the ECA product solutionis 85% HOCl to 15% NaOH. Depending on the operational parameters of theparticular apparatus and user requirement, the product solution ofhypochlorous acid may exhibit an FAC in the range of 20 ppm-1000 ppm.For example, hypochlorous acid produced at FAC's of about 100-200 ppmare suitable for basic sanitizing while higher FAC's, such as about 1000ppm, are useful in disinfecting, anti-microbial applications andhospital sanitizing applications. Thus, operation of the ECA system 1000embodied in any apparatus where the reactant solution includes sodiumchloride, and optionally citric acid, may result in a sanitizingsolution or an antimicrobial/disinfecting solution depending on theoperation parameters of that apparatus, as described herein. Onceelectrode activation has terminated, the ECA product solution may have astable shelf life. For example, the HOCl ECA product solution may have ashelf life of 30 days. In another example, the HOCl ECA product solutionmay have a shelf life of up to 60 days. As such, the ECA system 1000 canprovide a stable output of 100 ppm to 1000 ppm HOCl that has significantshelf life, enabling the ECA product solution to be bottled and used ata later date or sold. Both sanitizing solutions wherein the FAC is at orbelow 200 ppm FAC and disinfecting solutions where the FAC is over 200ppm can be stable outputs of the ECA system.

In some embodiments, halide salts or metal halide salts, such as sodiumbromide (NaBr) or potassium bromide (KBr) or iodine salts, may also beused in the ECA system.

In embodiments, the reactants may be pigmented to indicate the identityof the reactants. In embodiments, the pigments used may be selected tomatch the international training symbols for the particular kind ofsolution being generated.

In an embodiment, a possible electrolysis reaction that occurs is:2NaCl+2H₂O=>Cl2+H₂+2NaOH. The reaction can also be considered asfollowing: 2Cl⁻+2H₂O=>Cl₂+H₂+2OH⁻. A further reaction may occur with theproducts of this initial reaction: Cl₂+OH⁻=>HOCl+Cl⁻. The directions andequilibrium points of these reactions will depend on the reactionconditions and may be controlled by the control module 1010.

In another example, the starting material for the ECA system 1000 ispotassium carbonate. When the solution of potassium carbonate is exposedto the electrodes of the ECA system 1000, an electrolysis reactionoccurs. Electrolysis of the potassium carbonate produces at leastpotassium hydroxide, in certain embodiments in a mild alkaline solutionthat is useful as an environmentally friendly cleaner or degreaser.Other potassium containing species are also possible products of theelectrolysis reaction. Various other components and gases may also beproduced by the electrolysis reaction, such as hydrogen gas, oxygen, andozone. Various carbonate salts may be present in solution. The productsolution of potassium hydroxide may exhibit a pH in the range of 7.5 to11.2, or possibly higher or lower. Thus, operation of the ECA system1000 embodied in any apparatus where the reactant solution includespotassium carbonate may result in a cleaning solution depending on theoperation parameters of that apparatus, as further described herein.Once electrode activation has terminated, the product solution may havea shelf life of 2 to 14 days. As such, the ECA system 1000 can provide astable output of KOH that has significant shelf life, enabling the ECAproduct solution to be bottled and used at a later date or sold. Bothcleaning solutions wherein the hydroxide ion concentration is at orbelow 6 mM and degreasing solutions where the hydroxide ionconcentration is above 6 mM can be stable outputs of the ECA system.

In an embodiment, a possible electrolysis reaction that occurs is:K₂CO₃+H₂O=>2KOH+CO₂.

Potassium carbonate may be referred to as a carbonate salt or a metalcarbonate salt. Other members of the periodic family may be used inplace of the potassium to form a reactant used in the ECA system. Forexample, sodium carbonate (Na₂CO₃) or sodium bicarbonate (NaHCO₃) mayalso be used in the system. In embodiments, the reactants may bepigmented to indicate the identity of the reactants.

KOH in solution may react with the grease and oils in oily dirt duringcleaning. Since grease and oil contain lipids, the KOH reacts with themto undergo saponification in which a non-polar lipid molecule isattached to an OH⁻ radical. The non-polar end of the molecule dissolvesin the non-polar grease, while the polar OH⁻ radical is attracted to thewater molecules. This allows the complex to remain suspended in thewater allowing grease and oily dirt to be washed into the liquid andremoved during cleaning/degreasing. In other embodiments, micelles orhydrophobic-hydrophilic interactions may be involved in thecleaning/degreasing mechanism.

In yet another example, the starting material for the ECA system 1000 iswater, such as municipal water, so long as the water contains tracequantities of salts sufficient to initiate an electrolysis reaction inthe water. When the trace-containing water is exposed to the electrodesof the ECA system 1000, an electrolysis reaction occurs. Electrolysis ofthe water produces at least hydrogen ions (H⁺) and hydroxide ions (OH⁻).Hydronium ions (H₃ 0 ⁺) may also be produced. In this example,continuous electrode activation is required to maintain theelectrochemical activation of water as the disassociated water radicalscan only exist for a short period of time before re-associating backinto water molecules once the power is turned off and the electrodes arede-activated. However, if they are used in the dissociated state, thecleaning and other properties of ionized water may be realized. Suchelectrochemically activated water is useful in many applications, asdescribed herein.

Certain of the embodiments described herein produce one or more ofsanitizers, cleaners, antimicrobials, disinfectants and degreasers.Certain embodiments, such as the Medical Receptacle Design, are moreparticularly designed to produce a high FAC concentration disinfectant;however other embodiments described herein may also produce disinfectingsolutions.

FIG. 3 shows one embodiment of a system 301 for electrochemicallyactivating water. Here, an immersion wand 101, also described herein asan elongated immersive apparatus, has an immersion head 300 that isadapted to be immersed in an aqueous salt solution 3 in container 1. Insome embodiments, additional substances may be added such as smallamounts of citric acid.

The immersion wand 101 may optionally include an extendable shaft 200that connects immersion head 300 with a handle 100. The extendable shaft200 has an upper shaft 210 which may telescope from the lower shaft 230resulting in an adjustable length shaft.

An adjustable fastener 220 secures upper shaft 210 relative to lowershaft 230 to keep the extendable shaft 200 at a desired length.

A stabilizer assembly 240 connects to the extendable shaft 200 ofimmersion wand 101, connected to and extending from, the immersion head.The stabilizer assembly 240 holds the immersion wand 101 in a verticalposition generally in the center of container 1.

The solution 3 is an aqueous salt solution which may include common,non-toxic salts such as sodium chloride (NaCl), Potassium chloride(KCl), and potassium carbonate (K₂CO₃) or other salts, as describedherein.

A base unit 500 is connected to the immersion wand 101 through anumbilical 515 which provides electrical power to electrodes (not shownhere) in immersion head 300. Base unit 500 controls the system.

Base unit 500 has a user interface to allow a user to select varyingamounts of electrical power to be provided to the immersion head 300. Inone embodiment, the power selection controls 520 includes at least threebuttons indicating a low output for the first button, a medium outputfor the second button, and a high output for the third button.

These three buttons indicate varying amounts of time that power would beprovided to immersion head 300, wherein the high output indicated by thethird button would result in additional power being provided to theimmersion head or power being provided for a longer period of time thanit would be if the first or second buttons were selected. In otherembodiments, buttons may be provided for varying the properties of theelectrical power (such as current and voltage) applied to the solution.

For example, in a 3-stage power setting: low would apply to creatingcleaning fluid for mop buckets and small use cleaning amounts. Thiswould be approximately 2 to 4 minutes of power provided to the immersionhead 300.

For medium amounts, for use in midsized power equipment carpetextractors, automatic scrubbers, or larger cleaning buckets, a brewingtime of 4 to 6 minutes would be performed.

For large powered cleaning equipment and industrial cleaning needs, thepower would be provided for 7 to 9 minutes.

FIG. 4 depicts an elevational view of the immersion wand of FIG. 3 withstabilizer assembly. The stabilizer assembly 240 includes a collar 241which may be slidingly attached to the extendable shaft 200. Radiatingfrom the collar 241 are stabilizer arms 243 having adjustable connectors245 on their peripheral end. The adjustable connectors 245 are designedto removably attach to a container (1 of FIG. 3) into which it isplaced. The stabilizer arms may also be extendable to accommodatedifferent sized containers. Alternatively, the adjustable connectors 245may not be required if the stabilizer arms 243 are long enough to reston the top edge of the container.

Referring now to both FIGS. 4 and 5, an impeller 391 draws the solutioninto the immersion head 300 through the bottom of the immersion head300, the lower end ports 395 and side ports 387 and through an internalchamber 380. Internal chamber 380 includes electrode chips 311, 313positioned on either side of the internal chamber 380, typically abouteight (8″) inches from the bottom of the immersion head 300. When theelectrode chips 311, 313 are provided with a proper amount of electricpower, the electrode chips 311, 313 cause electricity to pass throughthe solution in the internal chamber 380, electrochemically activatingthe solution to create an ECA product solution.

The ECA product solution is then expelled back out of internal chamber380 of the immersion head 300 through upper end ports 395 to be mixedwith the solution 3 in container 1.

FIG. 6 shows an alternative embodiment of an immersion wand. Thisincludes an upper housing 703 which has a 2 inch to 2.5 inch diameter,in this embodiment. A top end of the upper housing 703 has a rubber grip701 that acts as a handle.

A pair of power supply lines 705, 707 run through the center of theupper housing 703 and connect to electrodes 713, 715, respectively.

The upper housing 703 connects to a wider lower housing 719 thatencloses submersible circulating fan 721. Lower housing 719 includesopenings to allow a fluid, such as an aqueous solution, to enter andpass through a portion of upper housing 703, past electrodes 713 and715. This requires the lower housing 719 and a portion of upper housing703 to be submerged in the aqueous solution.

The aqueous solution enters through the screen 723 covering the openingsin the lower housings 719 and exits through openings in the upperhousing covered by protective screen 711. The submersible circulatingfan 721 draws the water in through the lower housing 719 and causes itto flow past the electrodes 713, 715 and out of the openings and screen711.

A power consumption LED 717 is located on the upper side of the lowerhousing 719 and illuminates when power is being supplied to theimmersion wand 700.

It is to be noted that the immersion wand design may be employed inwater without adding any salts or other additives. Therefore, a cleaningdevice in which the immersion wand design is present and operating inthe solution as it is being used would be beneficial. This would be thecase of a floor or carpet cleaning machine which has its own 12 VDCpower supply. The immersion wand device can be placed in the cleaningsolution receptacle and it can operate continuously as the machinecleans the floor or carpet. Similarly, it could be used on ridingcleaners or scrubbers to produce a cleaner, but with no harmfulbyproducts.

FIG. 7 shows an alternative embodiment of the handle 100 being a loophandle 130. Loop handle 130 has a circular loop design within the innerloop grip 131. Loop handle 130 also includes indicator lights 113 on itsouter side to indicate operation of the device. It includes an exit port171 where the umbilical 515 from the immersion head exits the loophandle 130.

FIG. 8 shows another alternative embodiment of the handle 100 of thepresent invention, that is a straight handle 150. As with the otherembodiments of the handle 100, the umbilical 515 exits the handle at theexit port 171.

FIG. 8A shows another alternative embodiment of the present inventionthat includes an immersion head 400 that detaches from an upper housing703. The immersion head 400 is attached to the remainder of the deviceby an extension rod 405. This arrangement allows the immersion head 400to adjust to extend to the bottom of a large container, while stillbeing able to retract to fit into smaller containers.

A first part of a fastener 401 is attached to the lower part of theupper housing 703. The second part of the fastener 403 is attached tothe top of immersion head 400. When retracted the first part of thefastener 401 and the second part of the fastener 403 attach to eachother holding the immersion head 400 in its retracted position. In theembodiment shown, the fastener used is a twist lock-type fastener inwhich the first part 401 and second part 403 of the fastener are pushedtogether then twisted to lock. To unfasten them, it is twisted in theopposite direction then pulled apart.

This embodiment shares the same straight handle 151 and umbilical 515 asthe embodiment of FIG. 8. In FIG. 8A, the umbilical 515 presents a cord482 that connects to a control module/air pump 472 to receive both airand power.

In this embodiment, vanes 407 or louvers are employed instead of screens(as shown in previous embodiments). The vanes or louvers allow gasbubbles produced during the ECA to be more easily released from theinterior of the wand. In certain embodiments, the louvers may be openedor closed. In certain embodiments, the control module 1010 may controlthe degree to which the louvers are opened or closed.

This embodiment employs an air pump, similar to air pump 1012 describedin connection with FIG. 3. The air bubbles escape from the air pumpventing chamber 409 and agitate the solution causing mixing of thesolution and any undissolved reactants or additives.

FIG. 8B is a perspective view of another embodiment of an immersion head450, similar to that shown in FIG. 8A. As with the previous embodiment,it employs vanes 457 or louvers to direct escaping bubbles and thesolution out of the immersion head 450. It also includes an air pumpventing chamber 459 for the release of air pumped down through theimmersion head 450 by an air pump, similar to air pump 1012 of FIG. 3.

FIG. 8C is a view of the immersion head of FIG. 8B with its upperhousing 451 removed. The lower housing 453 is shown holding the internalstructures in place. The parallel generally rectangular electrodes 311,313 are positioned at the center of the lower housing 453. An extensionsupport assembly 460 receives and secures an extension rod, similar toextension rod 405 of FIG. 8A.

FIG. 8D is an exploded view of the immersion head 450 of FIG. 8B. Herethe extension support 460 is shown to be constructed from an extensionsupport collar 461 which fits inside of an extension support body 463.

FIG. 9 is an enlarged view of the top of the handle 100 of the immersionwand. It includes a power LED 181 that is lit when power is provided tothe immersion head 300. A fan LED 183 is lit when the fan (impeller) inthe immersion head 300 is operating. An alert LED 185 is lit when thedevice senses a power failure, such as a low voltage. In otherembodiments, various displays and indicators may be provided to provideinformation regarding various properties of the device, solution andprocess. For example, a timer may provide the time remaining and ascreen may provide the pH of the solution and the level of saltremaining.

FIG. 10 is an enlarged view of the base unit 500 which operates in asimilar manner as the control module 1010 of FIG. 3. In this embodiment,an operator can select one of three buttons, low output 521, mediumoutput 523 or high output 525 depending upon the strength of thecleaning fluid required. Base unit 500 also has a power confirmation LED527 which flashes indicating that power is being transmitted to theimmersion head 300. The base unit 500 is equipped with a time and theability to start and shut off power to the immersion wand or the PowerDisc. It also may include logic to determine when there is not enoughpower and light the Power LED.

When the power is operating correctly, it flashes the Power LED 181.

The base unit 500 is connected to and able to receive input from liquidsensor 397 of immersion wand 101, and liquid sensor 725 of the secondembodiment of the immersion wand 700. These indicate when there isenough aqueous solution to cover the functional portion of the immersionwand. The base unit 500 will only supply electrical power when theliquid sensors indicate that there is enough solution.

The base unit 500 also has the ability to reverse polarity of the powerbeing sent to the chips (electrodes). The reversal of polarity allowscharged particles that migrate to one or the other electrode to beremoved from the electrode. This is an effective way of cleaning theelectrodes.

The immersion wand is designed to be inserted into a number of differentreceptacles to operate and produce an ECA product solution. It can beused in tanks, mop buckets, jugs, bottles, and other devices andcontainers that hold water.

In addition, due to its compact design it may be inserted into areceptacle of an existing carpet scrubber, power floor scrubber, orother existing cleaning or sanitizer equipment.

In another embodiment, the immersion wand design operates off of a 12 VDC car voltage. In this embodiment, it can be inserted into a cleaningsolution reservoir of a riding floor scrubber to create the ECA productsolutions. It would be powered from the 12 V DC system of the ridingfloor scrubber.

The embodiments described herein may produce a sanitizer, disinfectant,glass cleaner, general purpose cleaner, heavy duty cleaner and degreaserfor use in a variety of devices and applications, including powerscrubbers, and carpet extractors.

FIG. 10A shows another embodiment of a base unit 550. This functions ina similar manner as base unit 500 shown in FIG. 10, but includes acontinuous use button. Instead of having three different levels ofoutput, the embodiment of FIG. 10A has a low output button 551 that mayfunction the same as button 521 of FIG. 10, a high output button 559that may function the same as 525, but includes a continuous use button559 which may cause the power to be continuously applied to theelectrodes. This is typically used to ionize water. The naturallyoccurring solutes allow the current to pass between the electrodesionizing water. The ionized water is intended to be used immediately,before it re-associates back into water.

In this embodiment, the handle 563 has a concave shape allowing the wandthat is used with this embodiment to snap into the concave handleallowing the user to easily carry both with one hand.

FIG. 11A, FIG. 11B, and FIG. 11C show still another embodiment of theECA system, embodied as an immersive apparatus. It includes all of thefunctional parts as the immersion wand designs, but physically has amuch lower elevational height. It is designed to be fully immersible andfit in a bucket in a solution and operates to activate a salt watersolution to create sanitizer and/or detergent solutions.

Here it is shown that the solution enters through ports 887 of a lowerhousing 819 drawn in by an impeller (not shown). The solution passesthrough an internal chamber having electrode chips thatelectrochemically activate the solution.

The electrochemically activated solution then passes out of ports 887 ofthe upper housing 803. A power consumption LED lights when the device isin operation.

The immersive apparatus may be capable of running on 12 volt power andmay have an LED built into the disc to confirm operation of Clean Discwhen submerged. The immersive apparatus may be tied into GFCI for safetywhen in operation and may employ larger power chips for maximumoperation.

In embodiments, the Immersion Wand Design or Immerse-A-Clean may reversepolarity every 2 minutes and rest after 2 minutes for 30 seconds.

In embodiments, the Immersion Wand Design may provide between 8 and 15amps of current to the solution in a receptacle depending upon theamount of solution to be activated and the concentration of salts insolution.

In embodiments, the Immersion Wand Design when ionizing water may becontinuously operating. The Immersion Wand Design may also have a 2minute cycle time and 10 minute cycle time for producing sanitizing andcleaning solutions.

In embodiments, the Immersion Wand Design may utilize flat, rectangularelectrodes.

In embodiments of the immersion wand design, various startingconcentrations of reactants may be used. For example, 3-12 g of NaCl maybe added to a ½ gallon of water. In other words, concentrations rangingfrom 36 mM to over 100 mM of NaCl may be used as a starting solution.More particularly, a smart chlorine solution may utilize 12 g NaCl in a½ gallon of water to provide approximately 108.5 mM NaCl. In anotherexample of a general purpose cleaner, 4 g of potassium carbonate may beadded to a half gallon of water to provide approximately 15.3 mMpotassium carbonate to start. Heavy duty cleaners and degreasers mayutilize additional potassium carbonate such as to provide approximately23 mM to start.

All the elements of the above described embodiments may be incorporatedinto other self-contained or other embodiments.

Embodiments of the ECA system may have a housing, such as housing 1002,that is constructed from a non-conductive plastic that is bis-phenol A(BPA)-free.

The immersion wand may include a clip to be attached to poweredequipment to hold the immersion wand and to allow on board use.

A power LED lamp may be included on the bottom of wand to assure user ofits operation. One or more LEDs on the handle may light to confirmoperation of wand when submerged.

A wet detection/moisture sensor may operate to insure that there is nooperation unless the device, or at least the electrodes, is submerged.

The base unit may contain one or more circuit cards with timers andground fault circuit interrupter (GFCI) to ensure user safety.

The wand length may be adjustable to set depth in water and user needs.

Another embodiment of the ECA system 1000 is the electrode-integratedreceptacle apparatus. All of the electrode-integrated receptacleapparatus described herein, such as the Portable Receptacle, EnlargedReceptacle and Medical Receptacle Designs, can be used as table topunits with circular, flat electrodes. One embodiment of theelectrode-integrated receptacle apparatus 1200 is shown in FIG. 12. Theembodiment in FIG. 12 is referred to as the “Trio™” design. In thisembodiment, the electrodes 1204 are disposed within a receptacle 1202that serves as a reservoir for the input of water or a reactantsalt-containing solution 1214. In this embodiment, the electrodes 1204may resemble flat circular plates or grids, such as those shown ascircular electrodes 1102 in FIG. 2. In this embodiment, the electrodesare placed horizontally and parallel to each other. A spacer is designedto keep these electrodes a specific distance apart.

The receptacle 1202 is designed to fit into the base 1208. Theelectrical contacts on the base 1208 make contact with receptaclecontacts 1226 on the bottom of the receptacle 1202 that connect to theelectrodes 1204. When the receptacle 1202 is properly placed on the base1208, power from a power supply 1210 is passed through the contact ofthe base 1208, into the receptacle 1202 and to the electrodes 1204. Theelectrical power provided causes an electrolysis reaction, such as anyof those described herein to occur in the receptacle 1202. The base 1208or the receptacle itself 1202 may have a display, such as a digitalreadout or digital user interface 1212 to indicate various parameters ofthe operation of the electrode-integrated receptacle apparatus 1200.

FIG. 12A is a perspective view of an embodiment of the apparatusconsistent with the schematic of FIG. 12. FIG. 12A shows theelectrode-integrated receptacle 1200 in its base 1208 operating toproduce an ECA product solution. In this embodiment, a light underneaththe receptacle lights when the solution is being created.

Also note that the digital UI 1212 shows a number of indicator lights.The UI 1212, as described herein, may be controlled by the controlmodule 1010 which is integrated into base unit 1208. This same operationmay also be used on the other embodiments such as that shown in FIG. 13.

FIG. 12B is a perspective view of the receptacle 1202 of the embodimentof the present invention shown in FIG. 12A.

FIG. 12C is a perspective view of the base 1208 of the embodiment of thepresent invention shown in FIG. 12A. In this view, the electricalcontact 1216 can be seen that make contact with those of the receptacle1202 when it is placed on the base 1208. An alignment feature is eithera protrusion or a recess that has a complementary shape on thereceptacle 1202 causing it to align the receptacle 1202 in the properlocation and orientation to have the electrical contacts 1216 meet thoseof the receptacle 1202.

The digital UI 1212 can easily be seen. It is driven by the controlmodule 1010 and may provide any number of indications or prompts to auser, as described herein.

FIG. 12D shows the bottom of the receptacle 1202. The receptaclecontacts 1226 are visible. These are sized and positioned to touch theelectrical contacts 1216 on base 1208 when the receptacle 1202 isproperly positioned on the base 1208. The receptacle alignment feature1218 on the base 1208 is the complement of the alignment feature 1228 onthe bottom of the receptacle 1202 causing them to fit together when thereceptacle 1202 is properly placed on the base 1208. A magnet 1230 inthe receptacle 1202 lines up with a magnet sensor 1206 in the base 1208.The control module 1010 identifies when the magnet sensor 1206 sensesmagnet 1230 indicating that the receptacle is properly positioned on thebase 1208. Power is provided when the receptacle is on the base 1208,and is not provided once the receptacle 1202 is removed.

FIG. 12E is a sectional view of the receptacle of FIG. 12B viewing thebottom of the receptacle. In this view the electrode 1204 is visibleindicating its circular shape and that it is positioned parallel to thebottom of the receptacle 1202.

In embodiments, the receptacle can hold 40 ounces of solution, thecurrent flow is reversible at the halfway point during the 5 minutecycle, the operating amperage is 4 amps, the operating voltage rangesfrom 110 to 240 volts, and the narrowing shape of the receptacle ensuresproper mixing.

In embodiments of the portable receptacle design, various startingconcentrations of reactants may be used. For example, 3 g of NaCl may beadded to 40 ounces of water to provide approximately 43.5 mM NaCl. Inanother example of a general purpose cleaner, 0.75 g of potassiumcarbonate may be added to 40 ounces of water to provide approximately4.6 mM potassium carbonate to start. Heavy duty cleaners and degreasersmay utilize additional potassium carbonate (e.g. 2 g) such as to provideapproximately 12.3 mM to start.

Another embodiment of the electrode-integrated receptacle apparatus 1200is referred to as the Medical Receptacle Design or the “Trio Rx™”design. This is similar to the apparatus 1200 described herein, but isdesigned to produce disinfecting solutions having up to 1000 ppm of FAC.This is intended for medically-related disinfecting applications. Thehigher FAC is effective against many common microbes includingMethicillin Resistant microbes (MRSA). The medical receptacle design isintended to use more NaCl and receive additional electrical power fromthe electrodes as compared with the portable receptacle design.

To dissolve the larger amount of salt, the Medical Receptacle Design mayfurther include an impeller, as described herein, in the receptacle 1202that rotates to agitate the salt. The impeller may be in the form ofpaddles at the bottom of the receptacle. The control module 1010 in thebase 1208 includes the logic to operate the impeller to dissolve thesalt before operating the electrodes. Optionally, there may be sensorsthat determine the amount of undissolved salt in the receptacle 1202that are sensed by the control module 1010. The control module 1010 thenoperates the electrodes at the appropriate time taking into account theamount of undissolved salt.

Further, this embodiment may operate for longer time periods, such asten minutes, to ensure reaction completion. In embodiments, thereceptacle can hold 64 ounces of solution, the current flow reversesevery 2.5 minutes during operation, the operating amperage is 10 amps,the operating voltage ranges from 110 to 240 volts.

In embodiments of the medical receptacle design, various startingconcentrations of reactants may be used. For example, 12 g of NaCl maybe added to a ½ gallon of water to provide approximately 108.5 mM NaClto start.

The Enlarged Receptacle Design, which may also be referred to as “TrioMaxx,” shares much of the same components of the Portable ReceptacleDesign with several notable exceptions. For example, it employs anenlarged receptacle 1202 to be able to make a larger amount of ECAproduct solution. It may employ titanium electrodes that are coated withplatinum, or any other electrode described herein, such as theiridium-coated electrodes, to resist corrosion and to have highelectrical conductivity. This results in a device that has a cycle timeof 3 to 5 minutes as opposed to the Portable Receptacle Design that hasa cycle time of 5 minutes. In embodiments, the receptacle can hold 64ounces of solution, the current flow is reversible at the halfway pointduring the 3 to 5 minute cycle, the operating amperage is 4 amps, theoperating voltage ranges from 110 to 240 volts, and the wide mouthdesign facilitates brewing of 64 ounces of ECA product solution.Electrodes used in the Enlarged Receptacle Design may be platinum and/ortitanium.

In embodiments of the enlarged receptacle design, various startingconcentrations of reactants may be used. For example, 4 g of NaCl may beadded to a ½ gallon of water to provide approximately 36 mM NaCl. Inanother example of a general purpose cleaner, 1.5 g of potassiumcarbonate may be added to a half gallon of water to provideapproximately 5.7 mM potassium carbonate to start. Heavy duty cleanersand degreasers may utilize additional potassium carbonate (e.g. 4 g)such as to provide approximately 15.3 mM to start.

FIG. 12F depicts an exploded view of the receptacle apparatus of FIG.12A.

Here grating 1224 can be seen that prevents undissolved additives frombuilding up around the electrodes 1204 and interfering with theirperformance.

FIG. 12G depicts an exploded view of another receptacle embodiment.

In this alternative embodiment, all parts having reference numbers thatare the same as those described above (without the appended “a”) serve asimilar function and perform in a similar manner.

This includes a receptacle 1202 a that fits into a base 1208 a. Contactbetween electrodes 1216 a and 1226 a cause power to flow from the base1208 a to the electrodes 1204 a in receptacle 1202 a.

Power is provided to the system by a power supply 1210 a.

It is shown here that a grating 1224 a stops additives, such as saltsfrom falling to the bottom of the container and affecting the operationof the electrodes 1204 a.

A digital user interface 1212 a interacts with the user to take commandsand to provide status of the system.

Another embodiment of the system 1000 is the instant flow apparatus 1300which is also referred to as a Continuous Flow Design or the“InstaFlow™” design. In this embodiment, water is received through anintake 1304 into an internal reservoir or electrode and reactant cell1320. An optional intake sensor 1329 monitors the amount of fluid flowover a period of time and/or the rate of fluid flow being received.Also, an optional intake valve 1331 operates under the control of thecontroller 1312 and interactively regulates the amount of fluid receivedand/or the rate of fluid flow. An optional backflow preventer mayprevent reactants from moving in a rearward direction into the watersystem. In addition, in embodiments, the system may contain varioussolenoids and valves to control the flow of fluids and air.

A salt is added to the water in the reservoir 1320. Alternatively, asalt-containing solution is taken into the apparatus 1300 via an intake1304 into the reservoir 1320. The salt-containing solution comes incontact with the two or more electrodes 1310. A controller 1312, similarto the controller 1010 of FIG. 3, provides, or controls the provisionof, electrical power to the electrodes 1310 to cause the electrochemicalreactions to produce an ECA product solution.

The salt-containing solution may be held in the reservoir 1320 for aperiod of time or the reservoir 1320 may be continuously emptied of theproduct solution through the product outflow 1308 and refilled withfresh salt-containing solution. Optionally, an outflow sensor 1333measures the rate of fluid flow and/or the accumulated fluid flow for adefined period of time. This information is provided to the controller1312 that interactively operates an optional outflow valve 1335 thatregulates the total amount of fluid released or the rate at which fluidis released.

The reservoir 1320 may optionally include an impeller 1322 for agitatingthe solution inside the reservoir 1320. The controller 1312 operates ina similar manner as the control module 1010 of FIG. 3 controllingvarious aspects and parameters of the system. In addition, thecontroller 1312 can adjust the rate in which the water is received aswell as the rate in which the solution is removed from the internalreservoir 1320. Therefore, the rate at which the solution passes overthe electrodes 1310 is controlled. The slower the solution passes overthe electrodes 1310, the more time that it experiences becomingelectrochemically activated. This causes an increase in the FAC (whenproducing the sanitizer solution, for example) and an increase in theconcentration of OH⁻ radicals (when producing the cleaning anddegreasing solutions, for example) or an increase in the active speciesin other embodiments. A user may input the amount of reactant used orFAC desired and the controller 1312 may automatically program operationof the apparatus 1300.

The controller 1312 may include or be in communication with the sensors1022 described herein to sense temperature, pH, FAC, current flow,solution level, and the other parameters noted herein and the like. Itmay also include additional sensors to monitor flow of water/solution inthrough the intake.

The controller 1312 may be operated by a user via manual means or via adigital user interface (UI) 1314. The apparatus 1300 may be powered by apower supply 1318, or other power means described herein.

FIG. 13A shows the Continuous Flow Design 1300 without the power supply1318, the intake 1304 and product outflow 1308. The outer housing 1302has a window for the digital UI 1314 which may have the features of theUI as described herein. It may include intuitive indications of theoperation of the apparatus 1300. As indicated for the portablereceptacle design above, there are operation indicators 1324 that arelights in a circular arrangement that sequentially light in a clockwisefashion when power is being provided in a first polarity to thesolution, and in a counter-clockwise fashion when power is beingprovided in a second polarity. The lights may also signify otheractivity, such as simultaneously flashing if an error has been sensed,or the system has run out of additives.

FIG. 13B shows water handling elements of the system for the ContinuousFlow Design 1300. Here an in-line filter 1326 filters out impuritiesfrom the tap water.

FIG. 13C shows the system electronics for the Continuous Flow Design1300. The controller 1312 is visible in this view.

The apparatus 1300 may have a reserve tank with automatic shut off.

In an embodiment, the Continuous Flow Design reverses current every 2minutes when in operation and provides a continuous flow of ECA productsolution of up to 2.5 gallons per minute. The Continuous Flow Designprovides up to 17 Amps of current to the electrodes. The system canadjust the flow rate past the electrodes to adjust the amount of ECAactivation of the solutions. The Continuous Flow Design can continuouslyoperate at voltages ranging from 110-240 V and amperages of 17 amps orso. The Continuous Flow Design may be used as a table top unit or awall-mounted unit. The Continuous Flow Design may utilize flat,rectangular electrodes.

In an embodiment, the continuous flow design may produce up to 450gallons of ECA product solution per tank of reactant starting solution.In embodiments, at least 19 to 39 ounces of sodium chloride/citric acidmixture may be utilized in generating at least 70 gallons of thesanitizer, at least 13 ounces of potassium carbonate may be used togenerate at least 65 gallons of the Heavy Duty Cleaner/Degreaser, and atleast 6 Ounces of potassium carbonate may be used to generate at least75 gallons of the Window and Glass Cleaner.

One of the uses for the products of the currently described system andmethod is in hydraulic fracturing, commonly called “fracking”. Frackingtypically requires large amounts of water with some sand and a smallamount of other additives. FIG. 13D is an example of the volumetriccomposition of fracking fluids. Here it can be seen that the frackingfluid is approximately 90% water by volume. Approximately 9% is sand andthe other additives make up approximately 0.5% by volume. The 0.5% ofthe other additives includes biocides such as Glutaraldehyde thateliminate bacteria in the water that produces corrosive by-products, aswell as other chemicals, (from “Volumetric Composition of Shale GasFracture Fluid”,http://www.shalegaswiki.com/index.php/Fracturing_fluid).

The fracking fluid is forced down into a natural gas or oil well farbelow the surface into geological formations under high pressure bylarge fluid pumps. Up to 2 million gallons of water per day may berequired to perform fracking for a single well. The biocide is about0.001% by volume of this amount and may be needed in amounts of 2000gallons of product per day.

Any of the embodiments described herein could be scaled to producelarger amounts of the ECA products. In particular, the continuous flowembodiment is well suited for use in connection with fracking. Referringnow to FIG. 13E, an enlarged continuous flow system is shown. Thisfunctions in the same manner and employs the same functional structuresas the continuous flow apparatus 1300 of FIG. 13, but is designed to bemuch larger to be able to provide the amount of ECA product required forfracking. In particular, the system may include a cell with an array ofmany electrodes as opposed to only a pair of electrodes.

Water to be used for fracking is shown here provided by a tanker truck1501. In alternative embodiments, water may be provided by a water lineleading to a water source such as a settling pool, pipeline, reservoiror other water source. The water is provided to the intake 1304. A salt,such as those described herein, is introduced into the water and mixedwith the impeller 1322. The controller 1312 provides power to theelectrodes 1310 in a manner to produce an ECA product that will be ableto perform the function of a biocide or other functions useful forfracking applications. In other embodiments, potassium salts may be usedto produce KOH used as a pH balancer. The ECA product exits theapparatus through the product outflow 1308 and into a holding tank 1503.

The ECA product is then provided to the fracking equipment that mixes itwith water and sand, adds anticorrosion chemicals and other additives,gels the components into a fracking fluid and provides the components toa high pressure pump (typically part of fracking equipment 1505). Thehigh pressure pump forces the fracking fluid through the casing of thewell 1507, and down the well 1509 to perform its function underground.

The non-toxic ECA products may be used to replace at least some of thebiocides currently used in fracking. The systems and methods describedherein may also be used to develop other additives, such as hydrochloricacid that helps dissolve minerals and initiate cracks in rocks.

FIG. 13F depicts an exploded view of an alternative embodiment of aninstant flow apparatus. Here are various pumps, valves, filters,sensors, etc. employed by the apparatus 1300 a. In this view thereservoir 1320 a is visible. Water filter 1326 a is also visible. FIG.13F is sectioned into three parts, each which is shown in subsequentFIGS., FIG. 13G, Fig, 13H and FIG. 13I.

FIG. 13G is an enlarged view of elements of the instant flow apparatusof FIG. 13F. The filter 1326 is shown here.

FIG. 13H is an enlarged view of elements of the instant flow apparatusof FIG. 13F. In this view, both the reservoir 1320 a and the filter 1326a are shown,

FIG. 13I is an enlarged view of elements of the instant flow apparatusof FIG. 13F. Here, intake valves 1340 can be seen. In this embodiment,three intake valves 1340 are shown but it is understood that a pluralityof intake valves 1340 may be used in the apparatus. For example, theplurality of intake valves 1340 may be useful for making a plurality ofsolutions readily. For example, a tank of starting solution containingreactants may be attached to the apparatus through the intake valve1340. In the example of this apparatus, three tanks may be attachedthrough the three intake valves 1340, each perhaps holding a differentsolution of starting reactants. For example, one tank could hold thesodium chloride/citric acid mixture, another holds potassium carbonatein sufficient quantity to produce a general purpose or glass cleaner,and yet another holds potassium carbonate in sufficient quantity toproduce a degreaser/heavy duty cleaner. In any event, reactant solutiontaken up through the intake valve 1340 may be mixed with water either inthe plumbing on the way to the reservoir 1320 a or electrolysis chamberor within the reservoir 1320 a or electrolysis chamber. In embodiments,the intake valve 1340 may take up water.

FIG. 13J depicts an exploded view of an alternative embodiment of aninstant flow apparatus, showing the system electronics. Here, controller1312 a, which may be a 200 amp power controller, and housing 1302 a areshown. On the housing 1302 a, a three-line input 1342 for reactantintake is shown.

FIG. 13K depicts an exploded view of the front panel assembly of analternative embodiment of an instant flow apparatus.

Here it can be seen that a front panel 1337 a has a latch 1339 a. Thislatch 1339 a attaches to the apparatus housing.

A digital User Interface (UI) 1314 a allows the user to interact withthe UI to receive input and provide status of the apparatus. The digitalUI 1314 a may comprise a liquid crystal display or any other displaytechnology.

FIG. 14 is a table showing sample operating specifications for variousparticular embodiments of the present invention. It is to be understoodthat these are being provided as examples of specific embodimentskeeping in mind that many variations and modifications of thesespecifications may also be used for additional embodiments of thecurrent invention.

Since the ECA product solutions are non-toxic, they can be used in avariety of settings and applications. ECA product solutions may be usedfor cleaning, sanitizing and disinfecting food, kitchen utensils,cooking implements, hands, skin or any surfaces that may come in contactwith microbes or dirt. Embodiments described herein may be deployed invarious settings/environments or ECA product solutions may be used invarious settings/environments/applications, such as: airplanes, trains,buses, taxis, cars, showers, bathrooms, schools, day cares, playgrounds,in situ microfiber cloth treatment, retail environments, hospitals,doctor's offices, medical facilities, wound care, veterinary facilities(e.g. as a halitosis treatment as well), pet stores, animal shelters,dental facilities (e.g. as an irrigant as well), nursing homes/eldercare, pharmacies, emergency triage units, hotels, cruise ships, boats,shipboard wastewater treatment, spas, pools, gyms, saunas, salons,delis, butcher shops, grocery/produce section (e.g. in the producesprayers), slaughterhouses, pelt cleaning, dairy farms (e.g. to cleanmilk production machinery), nut processing, mechanic shop,military/battlefield, mold remediation, laundry, warewashing, indoor airquality management, camping, third world/remote settlements, skinemollient, agricultural sprayer, plant mite killer, hydroponicsirrigation, greenhouses, agricultural potassium source,wineries/vineyards, hydraulic fracking and the like.

ECA product solutions may also be used in food preparation, such as inrestaurants and in fast food preparation, such as to clean fruits andvegetables or in warewashing. The ability to easily create ECA productsolutions useful in food preparation may enable the use of local producesince such local produce, which may not be subject to regulatoryinspection, can nevertheless meet regulatory standards. ECA productsolutions may be used in food manufacturing/bottling/processing and inaseptic packaging. For example, in order to sanitize produce on site ina restaurant, the lettuce must be sprayed or soaked in a sanitizingsolution. For large restaurants, keeping the quantity of sanitizingsolution needed to soak produce, such as large heads of lettuce, that isdiscarded immediately to mitigate cross-contamination may requiresignificant cost and storage. Utilizing the embodiments described hereinto produce ECA product solutions suitable for sanitizing mitigates theneed for maintaining an inventory of sanitizing solutions. Instead,sanitizing solutions can be made on demand in batches or in a continuousflow. Further, the only inventories required are the reactants and thegenerally compact embodiments.

In embodiments, the ECA system 1000 may be embodied as a produce sprayeror as a produce bath. For example, a produce sprayer may include anozzle connected to a reservoir of embodiments of the ECA system 1000 oran outflow from embodiments of the ECA system 1000.

The ECA product solutions may be used for improving air quality byadding it to humidifiers or vaporizers for the home or in large buildingair handling facilities. It is also safe enough for use in a nursery,especially if someone in the house has contracted a cold. Inembodiments, the ECA system 1000 may be integrated with the humidifier.For example, electrodes may be disposed within the reservoir of thehumidifier to produce an ECA product solution such that it is the ECAproduct solution that gets released into the air by the humidifier, viaany of the mechanisms by which humidifiers work. Use of the ECA productsolutions in humidifiers and air handling facilities may be useful tomitigate the effects of asthma and allergies. Further, the humidifierneed not be cleaned as frequently since the ECA product solution willclean, sanitize, and/or disinfect during use. It can be used in theexhaust for hot air furnaces. This will sanitize these hidden locations.Once in the air, ECA product solution can act as an airborne dustremover.

The ECA system, or its outputs, may be used in various form factors forhand and skin washing and sanitizing. In one embodiment of soapless handwashing, the ECA system may be deployed such that the outflow isdirected to faucets for hand washing. In another embodiment, awall-hanging dispenser may be filled with a stable output of the ECAsystem, such as the HOCl solution at a ppm below 200.

The ECA system may be integrated with various devices to produce ECAproduct solutions in situ, such as dishwasher/warewashing facilities,floor scrubber, washing machine/laundry facilities, produce sprayer,food washing bath, faucets (such as to provide soapless hand washing),shower heads, custodial sprayer, food sprayer/food bath, wall-mountedhand sanitizers, and the like. In certain embodiments, the ECA systemmay be retrofitted into existing devices. For example, a floor scrubbermay have an onboard ECA system to produce ionized water or KOH ondemand. In this example, the floor scrubber may have a reservoir. Theelectrodes used for ECA may be disposed within the reservoir. Control ofthe electrodes might be located among the controls for the floorscrubber itself such that a user of the scrubber can control productionof the ECA product solution while operating, or not operating, the floorscrubber. The ECA product solution may be dispensed onto floors by anoutflow from the reservoir. In another embodiment, the ECA system may beintegrated with warewashing facilities. For example, as a warewashingfacility takes up water for cleaning, the integrated ECA system may mixthe water with reactants and flow the reactant solution over electrodesprior to dispensing it to the warewashing facility, which then dispensesthe ECA product solution.

Wherever there are microbes and a need to sanitize/disinfect or if thereis a need to clean, the ECA product solutions created by embodimentsdescribed herein may be used.

While only a few embodiments of the present invention have been shownand described, it will be obvious to those skilled in the art that manychanges and modifications may be made thereunto without departing fromthe spirit and scope of the present invention as described in thefollowing claims. All patent applications and patents, both foreign anddomestic, and all other publications referenced herein are incorporatedherein in their entireties to the full extent permitted by law.

The methods and systems described herein may transform physical and/oror intangible items from one state to another. The methods and systemsdescribed herein may also transform data representing physical and/orintangible items from one state to another.

The elements described and depicted herein, including in flow charts andblock diagrams throughout the figures, imply logical boundaries betweenthe elements. However, according to software or hardware engineeringpractices, the depicted elements and the functions thereof may beimplemented on machines through computer executable media having aprocessor capable of executing program instructions stored thereon as amonolithic software structure, as standalone software modules, or asmodules that employ external routines, code, services, and so forth, orany combination of these, and all such implementations may be within thescope of the present disclosure. Examples of such machines may include,but may not be limited to, personal digital assistants, laptops,personal computers, mobile phones, other handheld computing devices,medical equipment, wired or wireless communication devices, transducers,chips, calculators, satellites, tablet PCs, electronic books, gadgets,electronic devices, devices having artificial intelligence, computingdevices, networking equipment, servers, routers and the like.Furthermore, the elements depicted in the flow chart and block diagramsor any other logical component may be implemented on a machine capableof executing program instructions. Thus, while the foregoing drawingsand descriptions set forth functional aspects of the disclosed systems,no particular arrangement of software for implementing these functionalaspects should be inferred from these descriptions unless explicitlystated or otherwise clear from the context. Similarly, it will beappreciated that the various steps identified and described above may bevaried, and that the order of steps may be adapted to particularapplications of the techniques disclosed herein. All such variations andmodifications are intended to fall within the scope of this disclosure.As such, the depiction and/or description of an order for various stepsshould not be understood to require a particular order of execution forthose steps, unless required by a particular application, or explicitlystated or otherwise clear from the context.

The methods and/or processes described above, and steps associatedtherewith, may be realized in hardware, software or any combination ofhardware and software suitable for a particular application. Thehardware may include a general-purpose computer and/or dedicatedcomputing device or specific computing device or particular aspect orcomponent of a specific computing device. The processes may be realizedin one or more microprocessors, microcontrollers, embeddedmicrocontrollers, programmable digital signal processors or otherprogrammable device, along with internal and/or external memory. Theprocesses may also, or instead, be embodied in an application specificintegrated circuit, a programmable gate array, programmable array logic,or any other device or combination of devices that may be configured toprocess electronic signals. It will further be appreciated that one ormore of the processes may be realized as a computer executable codecapable of being executed on a machine-readable medium.

While the disclosure has been disclosed in connection with the preferredembodiments shown and described in detail, various modifications andimprovements thereon will become readily apparent to those skilled inthe art. Accordingly, the spirit and scope of the present disclosure isnot to be limited by the foregoing examples, but is to be understood inthe broadest sense allowable by law.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the disclosure (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the disclosureand does not pose a limitation on the scope of the disclosure unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe disclosure.

While the foregoing written description enables one of ordinary skill tomake and use what is considered presently to be the best mode thereof,those of ordinary skill will understand and appreciate the existence ofvariations, combinations, and equivalents of the specific embodiment,method, and examples herein. The disclosure should therefore not belimited by the above described embodiment, method, and examples, but byall embodiments and methods within the scope and spirit of thedisclosure.

All documents referenced herein are hereby incorporated by reference.

1. A sprayer apparatus, comprising: a spray nozzle in fluidcommunication with a reservoir for an aqueous salt solution; at leasttwo electrodes spaced apart from each other integrated into thereservoir; and controller structured to apply electricity to the atleast two electrodes, wherein the controller controls an application ofelectricity to cause a first one of the at least two electrodes to bepositively charged and a second one of the at least two electrodes to benegatively charged; wherein the sprayer apparatus is configured toproduce air bubbles during application of electricity, wherein the airbubbles cause agitation and mixing of the aqueous salt solution.
 2. Thesprayer apparatus of claim 1, further comprising, a digital userinterface structured to display an operation indicator that changes witha polarity of the at least two electrodes.
 3. The sprayer apparatus ofclaim 1, wherein the controller is further structured to reverse apolarity of at least one of the at least two electrodes in response toreaching a pre-determined time during operation of the sprayerapparatus.
 4. The sprayer apparatus of claim 1, wherein the controlleris further structured to operate the sprayer apparatus at an amperage ofgreater than 4 Amps.
 5. The sprayer apparatus of claim 1, wherein the atleast two electrodes are iridium-coated.
 6. The sprayer apparatus ofclaim 1, further comprising, at least one sensor for determining anamount of at least one of a product or a by-product of at least one ofan electrochemical activation (ECA) product solution of the sprayerapparatus or the aqueous salt solution.
 7. The sprayer apparatus ofclaim 6, wherein the at least one sensor is selected from the sensorsconsisting of: a free available chlorine (FAC) sensor, a pH sensor, anelectrode temperature sensor, and an aqueous salt solution resistancesensor.
 8. The sprayer apparatus of claim 6, wherein the controllercontrols the application of electricity in response to the sensed atleast one of the product or the by-product.
 9. The sprayer apparatus ofclaim 6, wherein the at least one sensor is configured to measure atleast one parameter selected from the parameters consisting of: aconcentration of a product, a concentration of a reactant, and aconcentration of an active species.
 10. The sprayer apparatus of claim1, further comprising, an impeller disposed in the reservoir for mixingthe aqueous salt solution in the reservoir, and wherein the controllercontrols the impeller during the application of electricity.
 11. Thesprayer apparatus of claim 1, an impeller disposed in the reservoir formixing solution in the reservoir.
 12. The sprayer apparatus of claim 11,wherein the impeller is disposed on an inner surface of the reservoir.13. A sprayer apparatus, comprising: a spray nozzle in fluidcommunication with a reservoir for an aqueous salt solution; asubmersible housing with at least two electrodes spaced apart from eachother within the submersible housing, wherein the submersible housing isadapted to be immersed into the reservoir; and a controller electricallycoupled to the at least two electrodes, wherein the controller controlsapplication of electricity to cause a first one of the at least twoelectrodes to be positively charged and a second one of the at least twoelectrodes to be negatively charged, wherein the sprayer apparatus isconfigured to produce air bubbles during application of electricity, andwherein the air bubbles cause agitation and mixing of the aqueous saltsolution.
 14. The sprayer apparatus of claim 13, further comprising adigital user interface structured to display an operation indicator thatchanges with a polarity of the at least two electrodes.
 15. The sprayerapparatus of claim 13, wherein the controller is further structured toreverse a polarity of at least one of the at least two electrodes inresponse to reaching a pre-determined time during operation of thesprayer apparatus.
 16. The sprayer apparatus of claim 13, wherein thecontroller is further structured to operate the sprayer apparatus at anamperage of greater than 4 Amps.
 17. The sprayer apparatus of claim 13,wherein the at least two electrodes are iridium-coated.
 18. The sprayerapparatus of claim 13, further comprising, at least one sensor fordetermining an amount of at least one of a product or a by-product of atleast one of an electrochemical activation (ECA) product solution of thesprayer apparatus or the aqueous salt solution.
 19. The sprayerapparatus of claim 18, wherein the at least one sensor is selected fromthe sensors consisting of: a free available chlorine (FAC) sensor, a pHsensor, an electrode temperature sensor, and an aqueous salt solutionresistance sensor.
 20. The sprayer apparatus of claim 18, wherein thecontroller controls the application of electricity in response to thesensed at least one of the product or the by-product.
 21. The sprayerapparatus of claim 18, wherein the at least one sensor is configured tomeasure at least one parameter selected from the parameters consistingof: a concentration of a product, a concentration of a reactant, and aconcentration of an active species.
 22. The sprayer apparatus of claim13, further comprising, an impeller disposed in the submersible housingfor mixing the aqueous salt solution in the reservoir, and wherein thecontroller controls the impeller during the application of electricity.23. The sprayer apparatus of claim 13, an impeller disposed in thesubmersible housing for mixing solution in the reservoir.
 24. Thesprayer apparatus of claim 23, wherein the impeller is disposed on aninner surface of the reservoir.